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Emerson 51-DO-03 Oxygen Equipment User Manual

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1. 2 3 4 R E A 5 R R E T U R N WARRANTY REPAIR REQUESTED YES REFERENCE ORIGINAL ROSEMOUNT ANALYTICAL ORDER NO CUSTOMER PURCHASE ORDER NO NO PROCEED WITH REPAIRS INVOICE AGAINST P O NO NO CONTACT WITH ESTIMATE OF REPAIR CHARGES LETTER 0 A vuma PHONE NAME ADDRESS RETURN AUTHORITY FOR CREDIT ADJUSTMENT Please check appropriate box s WRONG PART RECEIVED REPLACEMENT RECEIVED DUPLICATE SHIPMENT REFERENCE ROSEMOUNT ANALYTICAL SALES ORDER NO RETURN FOR CREDIT RETURN AUTHORIZED BY WARRANTY DEFECT 24 6047 Emerson Process Management Liquid Division 2400 Barranca Parkway Irvine CA 92606 USA Tel 949 757 8500 lt gt 949 474 7250 http www raihome com E M E RSO N Rosemount Analytical Inc 2004 Pre eme Seller warrants that the firmware will execute the programming instructions provided by Seller and that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expira tion of the applicable warranty period Goods are warranted for twelve 12 months from the date of initial installation or eighteen 18 months from the date of shipment by Seller whichever period expires first Consumables such as glass elect
2. G i Noise rejection Barometric pressure Main sensor cal MS Exit Ene fa SN Auto Bar units mm Hg L Exit SE Press any key to enter the main menu Move the cursor to Program and press Enter F4 Move the cursor to Configure and press Enter F4 Move the cursor to Barometric pressure and press Enter F4 Use the ah and keys to move through the list of items To make a change press Edit F4 Use the arrow keys to change settings to the desired value and press Save F4 Bar meas The analyzer has an on board sensor that automatically measures barometric pressure To bypass the pressure sensor select Manual Be sure to enter the desired pressure in the third line During air calibration the analyzer will use the barometric pressure entered in this step no matter what the true pressure is Bar units Select the units in which barometric pressure will be dis played 37 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 10 MAIN SENSOR CALIBRATION PARAMETERS 1 Main sensor refers to the dissolved oxygen sensor G 5 Noise rejection Main sensor cal Security Sa 0 050 ppm Stabilize time 10 sec L Exit Enter 2 Stabilize 0 050 ppm Stabilize time 10 sec 0 0 Yoo Exit Edit T Exit Edit 38 Press any key to enter the main menu Move the cursor to Pro
3. viel ee ete t de etia 5 2 1 Suggested Arrangement of Handrail Mounting Assembly Maintenance Clamp Air Compressor Enclosure and 54eA Analvzer 8 2 2 Pipe e eet eter eee tete dene Remate ete ete a ERN 8 2 3 Attaching the Air Compressor Enclosure to the Handral 10 2 4 Assembling and Attaching the Handrail Mounting Assembly seeeeeeeeeenn 10 2 5 Installing the Sensor in the Washer Head Assembly 11 3 1 Power Input Relay and Output Wiring for 54eA 13 3 2 Model DO 03 Wiring Air Blast Compressor to Model 54eA Analyzer 115 Vac 14 3 3 Model DO 04 Wiring Air Blast Compressor to Model 54eA Analyzer 230 Vac 15 3 4 Wiring e RERUM RUM 16 3 5 Oxygen Sensor with Standard Cable A 16 3 6 Oxygen Sensor with Optimum EMI RFI Cable or Variopol Cable 16 4 1 Maih Display SCreen ei mente nee e mte es 17 5 1 Menu Tree for the 54eA Anahyzer emen nennen 18 5 2 EE 32 5 3 Figli E EE 32 5 4 Interval TImer EE 34 7 1 Sensor Current as a Function of Dissolved Oxygen Concentration 43 9 1 Palrts EE tante mms 52 9 2 Replacement Parts ce qe e eee eese deep 53 10 1 Simulate Dissolved Oxygen ennemis 59 10 2 Three Wire RTD CGonfouraton nennen 60 10 3 Simulating RTD
4. o o o alarm activates time delay FIGURE 5 2 Low Alarm 32 time delay To change the activation method press Edit F4 Use the key to scroll through the choices Process or Temperature Process means dissolved oxygen Press Save F4 to store the selection d The display returns to the Activate Process screen Press Exit F1 until the screen in Step 5 appears 8 Alarm setup for normal alarms a Move the cursor to the desired alarm setup and press Enter F4 b Use the and keys to move the cursor to the desired param eter Press Edit F4 Use the arrow keys to change the setting to the desired value and press Save F4 to store the value See the Figures 5 2 and 5 3 for an explanation of terms low alarm high alarm hysteresis and delay See Table 5 1 for allowed values and limits Relay default determines how the relay will operate if there is a fault or the analyzer is in hold Alarms can be forced on Close off Open or remain unchanged None high alarm setpoint alarm activates hysteresis 0 2 ppm hysteresis concentration alarm EG deactivates time i i time delay time delay FIGURE 5 3 High Alarm MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 6 CHANGING ALARM PARAMETERS continued Z Fault V Exit Edit J Disable Timeout 3600 sec d Exit Edit
5. 60 MODEL 00 03 04 SECTION 1 0 SPECIFICATIONS SECTION 1 0 SPECIFICATIONS COMPLETE SYSTEM INCLUDES sensor analyzer sensor washer head mounting hard ware and air compressor e AIR BLAST CLEANER system can keep DO sensors funtioning up to months or longer SENSOR MAINTENANCE is quick and easy e FEATURE PACKED ANALYZER on board pressure sensor for completely automatic air calibration large backlit display dual outputs three fully programmable alarm relays FEATURES AND BENEFITS The Model DO 03 04 is a complete system for the determination of dissolved oxygen in wastewater aeration basins It consists of a sensor an analyzer a handrail mounting assembly a sensor washer head and an air compressor A timer in the analyzer allows the user to customize the air blast cleaning cycle The Model DO 03 04 uses a membrane covered amperometric sensor A polarizing voltage applied to a gold cathode behind the membrane destroys oxygen diffusing through the membrane and keeps the concentration of oxygen in the sensor equal to zero The current generated by the cathode reaction is proportional to the rate of diffusion of oxygen through the membrane Because the concentration of oxygen in the sensor is zero the diffu sion rate and the current are proportional to the concentration of oxygen in the sample Sensor maintenance is fast and easy Replacing a membrane requires no special tools or fixtures A screw cap holds the pr
6. MODEL 00 03 04 SECTION 7 0 CALIBRATION DISSOLVED OXYGEN 8 Press Exit F1 four times to return to the main display NOTE If Hold was activated during calibration Hold Mode Activated will continue to flash in the main display Return the sensor to normal and deactivate Hold Refer to Section 5 5 step 9 9 During calibration the analyzer stores the measured current and calcu lates the sensitivity Sensitivity is the sensor current in nA divided by the saturation concentration of oxygen in ppm Typical sensitivity for a 499ADO sensor is 1 800 to 3 100 nA ppm 15 25 pA in air To view the sensitivity from the main display press any key to enter the main menu Press the key once Then press Enter F4 to display the diagnostic variables The sensitivity is the third line on the screen Note the units is nanoamps is microamps NOTE During calibration ERROR and WARNING messages may appear If an ERROR message appears press Exit F1 to leave and return to the previous screen If a WARNING message appears press Cont F3 to continue the calibration or press Abort F1 to leave Continuing the calibration after a warning message appears may cause substantial errors in the subsequent measurement Refer to Section 15 4 for assis tance 46 MODEL 00 03 04 SECTION 7 0 CALIBRATION DISSOLVED OXYGEN 7 4 CALIBRATING THE SENSOR AGAINST A STANDARD INSTRUMENT The analyzer and sensor can be calibrated against
7. Emerson Process Management Rosemount Analytical Inc 2400 Barranca Parkway Irvine CA 92606 USA Tel 949 757 8500 Fax 949 474 7250 http www raihome com Rosemount Analytical Inc 2004 Drawings and part numbers were updated on pages 5 6 7 and 51 m aw aL EMERSON Pro Manage cess Management Ground conduit to metal stiffener or to metal enclosure Use non flammable watertight conduit fittings plugs to preserve enclosure rating FORSIGTIG Brug uant ndelig vandt t forskruning som sikkerhed for bevaring af kapsiings klasse Jordforbindeise til metal kapsel VOORZICHTIG Aardieiding naar metalen profiel of naar metalen behuizing Gebruik onbrandbare waterdichte wartels pluggen om de beschermingsklasse te handhaven Kabelinnfor ng m jordes til metailavstiver eller til metalikapsiingen Bruk flammesikre og vanntette nipleriplugger siik at kapslingens tetthetsgrad opprettholdes Tubo di protezione per massa terra con elemento di ingresso in metallo o con custodia in metailo Utilizzare accessori connettori del tubo di protezione a tenuta stagna non infiammabili per assicurare i limiti di resistenza della custodis ligar a conducta de cabos terra atrav s de suporte ou inv lucro met licos Utilize bucins e acess rios ignifugos estanques preserva o da estanquecidade A CAUTION
8. LIVE VOLTAGES MAY BE PRESENT CURRENT QUTPUT 1 A WILL CAUSE SEVERE INJURY OR DEATH HARTO SINGLE Looe COMM MUL T EDROP OUTPUT AND POWER WIRING OUTPUT WIRING TB2 2 FOR 24VDC ONLY EARTH GROUNDS 2 3 POWER WIRING ALARM ALARM 3 4 DWG NO GROUND 454 FIGURE 3 1 Power Input Relay and Output Wiring for 54eA analyzer 13 MODEL 00 03 04 14 dad EDD DD TO COMPRESSOR TD COMPRESSOR SECTION 3 0 WIRING GND CURRENT gunmen 43 DuTYPur 2 EARTH QuTBUT t mani EE T 4 m E COMMUNICATION 2 5 2 3 4 5 7 250 ALARM i 2 ALARM 2 DANGER LIVE VOLTAGES ay BE CURRENT OUTPUT Es R DEATH em SINGLE M MITIDRDP HOT NEUTRAL FIGURE 3 2 Model DO 03 Wiring Air Blast Compressor to Model 54eA Analyzer 115 Vac MODEL 00 03 04 SECTION 3 0 WIRING EARTH CURRENT CURRENT 2 EARTH 1 e agit Toc ONES ec ruo Li COMMUN ICAT ION 182 1 2 3 4 5 amp dei i3 4 5 En ALARM Y vac TO
9. 20 min time out is selected hold mode will automatically disengage after being on for 20 minutes NOTE Selecting Enable hold or 20 min timeout does not put the analyzer in hold It only allows the user to put the analyzer in hold when the analyzer is in calibrate mode 9 Using hold If hold was enabled in step 8 above the hold screen will appear as soon as the user enters the Calibrate menu To activate Hold press Edit F4 Use the 4 key to change Off to On and press Save F4 Hold Mode Activated will be displayed Outputs and relays will go to the values programmed in step 7b Hold Mode Activated will continue to flash in the main display even after the user has left the Calibrate menu To deactivate hold enter the Calibrate menu and press Edit F4 Use the 4 key to change On to Off and press Save F4 Press Exit F1 twice to return to the main display MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 6 CHANGING ALARM PARAMETERS 1 This section describes how to configure the analyzer alarms Alarms 1 2 and 3 can be assigned to dissolved oxygen or temperature In addition alarm 1 2 or 3 can be configured as a feed limit timer or as an interval timer see steps 10 and 11 Alarm 4 is always a fault alarm 2 Press any key to enter the main menu Move the cursor to Program and press Enter F4 3 Move the cursor to Configure and press
10. 5 to 122 F 15 to 50 C assuming intermittent operation Power Code 03 115 VAC 60 Hz or 100 VAC 50 60 Hz single phase 1 3 to UL 1 4 A starting current 3 88 A insu LISTED lation class B UL approved Code 04 220 VAC 50 Hz single phase 0 6 A starting current 1 5 A insulation class A CE approved SPECIFICATIONS AIR BLAST CLEANER SYSTEM WASHER HEAD Process connection 1 1 2 inch PVC pipe socket Dimensions diameter x length 2 1 2 x 10 3 4 inches 64 x 273 mm Wetted materials PVC Noryl Viton Pipe boom 1 1 2 inch schedule 80 PVC maximum length 12 feet 3 6 m past handrail mounting clamp Pipe boom is supplied by customer Maximum distance between compressor and sensor 25 ft 7 6 m ABSH is supplied with 25 ft 7 6 m of air hose SECTION 1 0 SPECIFICATIONS SPECIFICATIONS HANDRAIL MOUNTING ASSEMBLY Materials of Construction Weather cap Schedule 40 PVC Pipe clamp and bracket Aluminum Clevis zinc plated steel U bolts nuts and bolts zinc plated steel Washers stainless steel SHIPPING INFORMATION The Model DO 03 04 is shipped in a single container Shipping weight is 38 lbs 17 5 kg PLANT AIR SYSTEM REQUIREMENTS for customers using plant air in place of air compressor Pressure 20 psig 239 kPa abs Flow 0 50 SCFM 14 L min at STP Air hose customer supplied compatible with 1 4 inch barbed fitting for connection at washer head MODEL 00 03 04 SECTION
11. Exit SES ei Outputs Alarms Exit Enter emm 1 control Output 1 setup Output 2 control Exit Enter 2 Outout Measurement Control Mode L Exit SEET Process d 2 Press any key to enter the main menu Move the cursor to Program and press Enter F4 3 Move the cursor to Configure and press Enter F4 4 Move the cursor to Outputs and press Enter F4 5 Five menu headers relate to outputs Each output has a control head er and a setup header The fifth header allows the output hold feature to be configured NOTE The 54eA analyzer be ordered with optional PID control feature The version of the 54eA analyzer provided with the DO 03 04 does not have control Although the control head er appears in this screen it is not activated To access a header move the cursor to the desired header and press Enter F4 6 Output Control Settings a Move the cursor to the desired output control header Press Enter F4 With the cursor on Output Measurement press Enter F4 Press Edit F4 Use the key to scroll through the choices Process and Temperature Process means dissolved oxygen Press Save F4 to store the selection The display returns to the Output Process screen Press Exit F1 until the screen in Step 5 appears 29 MODEL 00 03 04
12. codes and standards for electrical equipment Electrical installation and wiring must be done by qualified personnel The five holes in the bottom of the Model 54eA enclosure accept 1 2 in PG 13 5 strain relief connectors or con duit fittings The rear openings are for power and alarm relay wiring The left front opening is for sensor wiring and the right front opening is for analog output wiring Seal unused openings with conduit plugs 3 2 POWER ALARM AND OUTPUT WIRING Figure 3 1 shows the power relay and current output terminals For access to the terminals loosen the screw hold ing the protective cover in place and remove the cover Make power and alarm connections on TB3 Make analog output wiring connections on TB2 A DANGER Live voltages may be present Will cause severe injury or death Alarm contacts are dry i e not powered and are normally open Refer to Section 1 0 for relay specifications Refer to Figure 3 2 or 3 3 for details on how to wire the Model ABSH air blast system to the 54eA analyzer Figure 3 2 is for Model DO 03 115 Vac 60 Hz Figure 3 3 is for Model DO 04 220 Vac 50 Hz NOTE The 54eA analyzer has four alarm relays Relays 1 2 or 3 are normally open NO and can be used to operate the air blast cleaner The wiring diagrams show alarm relay 3 being used The relay used for the air blast cleaner MUST be configured as an interval timer See Section 5 6 for programming details For best EMI
13. h NEBEZPECI ZARIZENI POD NAPETIM S VAROVANI Zemnici vodic musi byt vodive spojen s kostrou pristroje Pouzivejte nehorlave vodotesne pruchodky abyste zachovali stupen kryti pristroje M DANGER LIVE VOLTAGES MAY BE PRESENT When fuse or this cover is removed will cause severe injury or death A For continued protection against fire replace only with fuses of specificed voltage and current ratings Fuses are located under this cover Odstraneni pojistky nebo tohoto krytu muze zpusobit vazne zraneni nebo smrt CAUTION VAROVANI A Poskozene pojistky nahrazujte pouze pojistkami se stejnym jmenovitym napetim proudem Pojistky jsou umisteny pod timto krytem AA PELIGRO VOLTAJE PUEDE ESTAR PRESENTE Cuando los fusibles o esta cubierta son removidos causar severas lesiones o muerte La toma tierra debe hacerse a un contrafuerte d metal a la caja met lica Utilice accesorios enchufes no inflamables y estancos al agua para preservar las especificaciones de la caja UBESKYTTET SPENDING Hvis sikringen eller denne p skrift tjernes kan dette medfore alvorlige kv stelser eller d d FORSIGTIG ATENCION Para una proteccion continua contra el fuego reemplace solamente con fusibles de voltaje y corriente especificados Los fusibles se encuentran debajo de esta cubierta Brug kun sikringer med n rmere angivet sp n
14. silicone Cathode Gold not normally wetted Accuracy 0 2 ppm at 25 C Repeatability 0 05 ppm 25 C Response time 25 sec to 63 of final reading at 25 C Pressure 0 to 65 psig 0 to 549 kPa abs Temperature 32 to 122 F 0 to 50 C Process connection 1 inch MNPT Electrolyte volume 25 mL approx Cable length standard 25 ft 7 6 m Cable length maximum 300 ft 91 m SPECIFICATIONS 54EA 01 ANALYZER Enclosure Epoxy painted light gray cast aluminum NEMA 4X IP65 144 x 144 x 132 mm 5 7 x 5 7 x 5 2 in DIN size panel cut out Front Panel Membrane keypad with tactile feedback Three green LEDs indicate alarm status Red LED indicates fault condition Display Three line back lit dot matrix LCD 70 x 35 mm First line is oxygen reading Second line is tem perature and current output Third line is user selectable Character heights 1st line 16 mm 0 6 in 2nd and 3rd lines 7 mm 0 3 in Power 115 1095 50 60 Hz 6 8 230 x 1096 50 60 Hz 696 8 W RFI EMI EN 61326 LVD EN 61010 1 SECTION 1 0 SPECIFICATIONS Outputs Two 4 20 mA or 0 20 mA isolated outputs Continuously adjustable Outputs can be assigned to oxygen or temperature Output dampening is user selectable Maximum load at 100 200 Vac is 550 ohms Output Accuracy 0 05 mA Alarms Relays 1 2 and 3 are assignable to oxygen or temperature One relay can also be used as an interval timer
15. 1 20 200 90 130 C See alarm 2 Oxygen Rosemount standard ppm C mA mA English Sensor current Output 1 current 21 MODEL 00 03 04 TABLE 5 1 Program Settings List continued ITEM CONFIGURE B Outputs Section 5 5 1 Output 1 a Measurement b Control Output 1 Setup a Current b Dampening c Hold mode d Fixed hold value e Fault value Output 2 a Measurement b Control Output 2 Setup Hold feature C Alarms Section 5 6 1 Alarm 1 Activation method b Control mode Alarm 1 setup a Configuration b Hysteresis if oxygen ppm if oxygen ppb if oxygen 96 saturation if temperature c Delay time d Relay fault Alarm 2 Activation method b Control mode Alarm 2 setup a Configuration CHOICES Oxygen or temperature Normal 4 20 mA or 0 20 mA 0 299 sec Hold last value or go to fixed value 0 22 mA 0 22 mA Oxygen or temperature Normal See output 1 Enable disable or 20 min timeout Oxygen or temperature Normal Low high or off 0 to 20 ppm 0 to 999 ppb 0 to 20096 0 to 10 0 99 sec none open closed Oxygen or temperature Normal Low high or off Rest of alarm 2 setup is the same as alarm 1 Alarm 3 setup is the same as alarm 1 Alarm 4 Alarm Feed limit timer a Feed limit b Timeout value Interval timer a Select alarm b Interval time c Repeats d On time e Off time f Recovery time 22 Fault or of
16. 1 Trim output 2 S A Exit Edit P From the main display press any key to obtain the main menu With the cursor on Calibrate press Enter F4 NOTE If Hold was enabled in Section 5 6 the hold screen will appear To activate hold refer to Section 5 6 step 11 Move the cursor to Output trim and press Enter F4 The warning screen reminds the user that the output currents will be affected Pres Cont F3 to continue Use the or keys to move the cursor to the desired output and press Enter F4 Select Cal point 1 0 or 4 mA or Cal point 2 20 mA Move the cursor to Meter and press Enter F4 Measure the output current with a calibrated ammeter Use the or keys to change the display to match the ammeter reading and press Save F4 Move the cursor to the other Cal point and select it Repeat step 6 NOTE If Hold was activated during calibration Hold Mode Activated will continue to flash in the main display Return the sensor to normal and deactivate Hold Refer to Section 5 6 step 11 49 MODEL 00 03 04 SECTION 9 0 SECTION 9 0 MAINTENANCE 9 1 ANALYZER MODEL 54eA 01 The Model 54 01 analyzer provided with the Model DO 03 04 system requires little routine maintenance Clean the analyzer enclosure and front panel by wiping with a clean soft cloth dampened with water A mild deter gent solution can also be used Do not use solvents like alcohol that might cause a b
17. 1 Analyzer Model 546A 01 breed e dee eed Hb diee 50 9 2 Oxygen Sensor Model AOOADO DA 50 9 3 eu 52 9 4 Air Blast Sensor Washer se dasa GEESS 53 10 0 TROUBLESHOOTING iano ccccccsctecceceviti 54 QE MEEO VE 54 10 2 Troubleshooting When a Fault Message is Showing sees 54 10 3 Troubleshooting When No Fault Message is Showing Temperature 56 10 4 Troubleshooting When No Fault Message is Showing 56 10 5 Troubleshooting Not Related to Measurement Problems 59 10 6 Simulating Inputs Dissolved Oxygen sse emen 59 10 7 Simulating WE ue 60 11 0 RETURN OF MATERIALS eee irent rettet Eege EEN 61 LIST OF TABLES Table TUE eene eee tede ra A eei i ERE Page 5 1 Program Settings Det edd eed edd eoe ide d ust ede dde en dod de e dde 21 5 2 Controller Mode Priority Chart 40 9 1 Replacement Parts a teh d re E 50 MODEL 00 03 04 TABLE OF CONTENTS LIST OF FIGURES Section Title Page 1 1 Suggested Arrangement of Handrail Mounting Assembly Maintenance Clamp Air Compressor Enclosure and 54eA Analvzer 4 1 2 Analyzer Direnslons oio GR REQUE od e ERE d 4 1 3 Enclosure DimensloHs rds ht EE o geed 5 1 4 Standard Sensor with Integral Cable enn 5 1 5 Air Blast Washer Head
18. 2 ERU 0 00 ppm 20 mA 20 00 ppm Output 1 12 00 mA S Exit Edit 2 2 Press key to enter the main menu Move the cursor to Program and press Enter F4 3 Move the cursor to Output setpoints and press Enter F4 Move the cursor to the desired output and press Enter F4 This screen confirms that changes to output 1 are going to be made Press Cont F3 to continue Otherwise press Abort 1 This screen shows the present settings for Output 1 If the output was configured to be 0 20 mA the first line will show OmA instead of 4mA The live current output is shown on the third line Move the cursor to the desired line and press Edit F4 Use the arrow keys to change the setpoint Press Save F4 to store the new value Press Exit F1 to return to the screen in step 4 Choose the other output and continue 25 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 3 TESTING OUTPUTS AND ALARMS 1 For testing purposes the analyzer can be programmed to generate simulated outputs and to activate and deactivate alarms Output setpoints Simulated tests Configure Exit Enter Test output 2 Test alarm 1 ER Test output 1 Y Exit Enter 9 WESTER 10 00 mA Simulating output Test alarm 1i Open Simulating alarm 26 K Exit Edit 2 K Exit Edit 2 2 Press key to enter
19. 4 Set the remainder of the display parameters Use the ah and keys to choose the desired parameter Then press Edit F4 Use the key to move the cursor to the desired selection Press Save F4 to store Temp units C or F Output 1 mA or of full scale Output 2 mA or of full scale Language English Francais Espa ol Deutsch Italiano Display left sensor current 1 alarm 1 setpoint no units alarm 3 setpoint no units or blank Display right sensor current I alarm 2 setpoint no units alarm 3 setpoint no units output 2 or blank Display Contrast 00 lightest 99 darkest the display contrast changes as the number changes Timeout Timeout returns the display from any other screen 7 to the main display if no key is pressed before the Timeout value timeout value is exceeded Polling address Identifies analyzer in multi drop HART applications SECURITY CAUTION The analyzer uses the timeout value to activate security Once the analyzer is unlocked by entering a security code security will not re activate until a display timeout occurs If timeout has been turned off security will never reactivate MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 5 CHANGING OUTPUT PARAMETERS 1 This section describes how to configure the analyzer outputs Outputs can be configured to represent dis solved oxygen or temperature Output setpoints Simulated tests Configure A
20. 50 nA Zeroing the sensor before the zero current has reached a stable minimum value will lead to low results Allow adequate time possibly as long as overnight for the sensor to stabilize before starting the zero rou tine 10 2 3 Temperature error low or high Temperature error usually means the RTD is open or shorted or there is an open or short in the connecting wiring First verify all wiring connections including wiring connections in the junction box if one is being used Next dis connect the RTD IN SENSE and RETURN leads at the analyzer Be sure to note the color of the wire and where it was attached Measure the resistance between the RTD IN and RETURN leads The resistance should be close to the value in the table in Section 10 7 2 If the temperature element is open or shorted the sensor should be replaced In the meantime use manual temperature compensation 10 2 4 Sense line open The 499ADO oxygen sensor uses a Pt100 in a three wire configuration see Figure 10 2 The in and return leads connect the RTD to the measuring circuit in the analyzer A third wire called the sense line is connected to the return lead The sense line allows the analyzer to correct for the resistance of the in and return leads and to cor rect for changes in lead wire resistance caused by changes in ambient temperature If the sense line is open check all wiring connections including connections at a junction box Next verify that the sense line is op
21. COMPRESSOR L 1 VE VOLTAGES i ij BE PRESENT COMPRESSOR NEUTRAL 230 VAC POWER FIGURE 3 3 Model DO 04 Wiring Air Blast Compressor to Model 54eA Analyzer 230 Vac 15 MODEL 00 03 04 SECTION 3 0 WIRING 3 3 SENSOR WIRING 3 3 1 General The wiring label which is shown in Figure 3 4 is a general purpose label It has wiring infor mation concerning other sensors for example oe Sms Shield contacting conductivity and pH that can be E Te Return stem used with the 54eA instrument platform For measurement of oxygen only terminal strip 2 RI RE gt a Flaw conned co Fe e 1 int e S 3 3 2 Wiring the Oxygen Sensor INDUCTIVE CONDUCTIVITY LU Figure 3 5 shows how to wire the oxygen sen 5 T Common ic 1443 Ido Connection sor to the analyzer SEA 3 Gry Orive 1t s t Remote P A pH iS Although it is not standard with the Model DO a 183410 cmn SIE LU e 03 04 an optional quick disconnect Variopol H e D 5 Grn Rec ive RT
22. Default Default Default Default Default Hold Hold Default Default Default Normal Normal pee Hold Mode Default Default Default Condition Closed Interval Timer Feed Limit Closed EFE RE CHEN NR Simulate tests 1 Indicates the state IF that item has been configured or selected i e if it is an interval timer or a feed limit timer or it is the one being tested Unconfigured or unselected items are not affected by that mode Condition Definitions 1 Normal refers to conditions when no other mode is present 2 Fault means the instrument has diagnosed a fault condition A fault message is displayed and the red LED is on Interval Timer means the timer sequence is occurring Hold Mode occurs when hold is activated by the operator i e during calibration Feed Limit occurs when a feed limit timer has reached its limit and is turned off after being on for too long Simulate tests are described in Section 5 4 Action Definitions 1 Normal is determined by process conditions or how the item has been configured Section 5 6 Open is a deenergized alarm relay alarm off Default is the setting configured for each item if there is a fault Section 5 6 Closed is an energized alarm relay alarm on Hold is the setting for the current output configured in Section 5 5 fixed mA value or the last normal value Prior is the state the alarm had before that mode occurred Test is the v
23. J 26 2 C 12 0mA l Feed limit alarm 1 1000ppm 9 Alarm 4 setup Alarm 4 is a dedicated fault alarm When a fault condition exists the red LED on the front display will light a b From the menu header screen step 6 move the cursor to Alarm 4 setup To disable the alarm press Edit F4 and use the key to change the Fault to Off 10 Feed limit timer setup Alarm 1 2 or 3 can be configured as a feed limit timer The feed limit timer prevents overfeeding of treatment chemicals by automatically turning off the relay after a timeout period a From the menu header screen step 6 move the cursor to Feed limit timer Press Enter F4 With the cursor on Feed limit press Edit Use the key to scroll through the choices disable AL 1 AL 2 and AL 3 Press Save F4 to store the selection Move the cursor to Timeout Press Edit F4 and use the arrow keys to change the timeout to the desired value Press Save F4 to store the setting Operation of the feed limit timer When a feed limit alarm has timed out Feed limit alarm 1 if alarm 1 was chosen appears in the display At the same time the red FAIL LED will light and alarm 4 will close if not turned off and the selected feed limit relay alarm 1 will open de energize All other alarms and current outputs will remain unchanged The relays remain in the state described until the Ack F2 k
24. RFI protection shield the output cable and enclose it in an earth grounded rigid metal conduit Connect the outer shield of the output cable to the earth ground connection on TB2 see Figure 3 1 Keep sensor and output signal wiring separate from power wiring Do no run sensor and power cables in the same conduit or close together in a cable tray AC wiring must be 14 gauge or greater Be sure to connect earth ground from the power cable to the nearby ground lug A good earth ground is necessary for proper operation of the analyzer Provide a switch or breaker to disconnect the analyzer from the main power supply Install the switch or breaker near the analyzer and label it as the disconnecting device HI WARNING RISK OF ELECTRICAL SHOCK AC connections and grounding must comply with UL 508 or local electrical code DO NOT apply uw power to the analyzer until all electrical connections are verified and secure 12 MODEL 00 03 04 SECTION 3 0 WIRING ENCLOSURE EARTH GND CURRENT CURRENT OUTPUT 2 EARTH QuTPUT HART T DND COMMUNICATION B2 1 2 3 4 5 ele elele e FOR 24VDC ONLY 1 2 3 24 GND VDC e elelelelele e e e e e 1 2 3 4 5 5 7 8 9 19 11 12 119 NEUTRAL 230 ALARM 1 ALARM 2 ALARM 3 NC COM L ALARM 4 1 IN DANGER
25. c L Exit SES d gt Exit Edit HIG LOSE 1025 1 C Ce m Esc Save d 42 2 From the main display press any key With the cursor on Calibrate press Enter F4 NOTE If Hold was enabled in Section 5 5 the hold screen will appear To activate hold refer to Section 5 5 step 9 3 Press the key twice to move the cursor to Adjust temperature then press Enter F4 4 Press Edit F4 to adjust the temperature The screen below will then appear Using the arrow keys enter the correct temperature and press Save F4 The controller will enter the value in memory To abort the change press Esc F3 Press Exit F1 three times for the main display NOTE If Hold was activated during calibration Hold Mode Activated will continue to flash in the main display Return the sensor to normal and deactivate Hold Refer to Section 5 5 step 9 MODEL 00 03 04 SECTION 7 0 CALIBRATION DISSOLVED OXYGEN SECTION 7 0 CALIBRATION DISSOLVED OXYGEN 7 1 INTRODUCTION As Figure 7 1 shows oxygen sensors generate a current directly proportional to the concentration of dissolved oxygen in the sample Calibrating the sensor requires exposing it to a solution containing no oxygen zero stan dard and to a solution containing a known amount of oxygen full scale standard The zero standard is necessary because oxygen sensors even when no oxygen is present in
26. disables 23 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 1 CHANGING ALARM SETPOINTS 1 Before changing alarm setpoints be sure that alarms are properly configured See Section 5 6 Alarm setpoints Output setpoints Simulate tests K Exit Enter e Alarm 1 setpoint Alarm 2 setpoint Alarm 3 setpoint Exit DESEN 0 000 ppm S Exit Edit 24 Press any key to enter the main menu Move the cursor to Program and press Enter F4 Press Enter F4 Move the cursor to the desired alarm and press Enter F4 A screen like the one shown will appear The alarm is a low alarm and the setpoint is 0 00 ppm Press Edit F4 Use the arrow keys to change the setpoint Press Save F4 to store the new value Press Exit F1 to return to the screen in step 4 Choose a new alarm MODEL 00 03 04 5 2 RANGING THE OUTPUTS SECTION 5 0 SOFTWARE CONFIGURATION 1 Ranging the outputs means assigning values to the low 0 or 4 mA and high 20 mA outputs Before rang ing the outputs be sure the outputs are properly configured See Section 5 5 e Alarm setpoints Output setpoints Simulated test Exit Enter a Output 1 setpoints Output 2 setpoints CAUTION Current Output 1 will be Exit Enter affected KE Cont y
27. mounted on the basin handrail See Figures 2 1 and 2 2 2 2 3 Installing the air compressor enclosure The air compressor is in a NEMA 4X fiberglass enclosure Figure 2 3 shows how to attach the enclosure to a handrail 1 Locate the enclosure within 25 ft 7 6 m of the sensor 2 sure the ambient temperature is between 5 and 122 F 15 to 50 C Do not expose the enclosure to direct sunlight The operating temperature for the air compressor might be exceeded FIGURE 2 2 Pipe Mounting 2 2 4 Installing the handrail mounting assembly The handrail mounting assembly PN 24048 00 is shipped completely disassembled Assemble and attach the mounting assembly to the handrail Refer to Figure 2 4 The spring pin shipped with the handrail mounting assembly is not needed Do not attach the boom clamp to the clevis yet Attach the maintenance bracket PN 24044 00 to the handrail See Figure 2 1 2 2 5 Assembling the pipe and pipe clamp Slide the PVC pipe boom through the handrail mounting pipe clamp Tighten the bolt to keep the clamp from sliding off Use 1 1 2 inch schedule 80 PVC piping Distance between the clamp and the end of the pipe should not exceed 12 feet 3 6 m See Figures 2 1 and 2 4 MODEL 00 03 04 SECTION 2 0 INSTALLATION 2 2 6 Installing the sensor in the washer head assembly 1 Remove the sensor from its box Remove the plastic protective cap from the end of the sensor Save the Replace the k
28. new sensor or a rebuilt sensor is first placed in service The current usual ly stabilizes after a few hours Is the sample flow within the recommended range High sample flow may cause erratic readings Refer to the sensor instruction manual for recommended flow rates Gas bubbles impinging on the membrane may cause erratic readings Orienting the sensor at an angle away from vertical may reduce the noise The holes between the membrane and electrolyte reservoir might be plugged Refer to Section 10 4 2 Verify that wiring is correct Pay particular attention to shield and ground connections Is the membrane in good condition and is the sensor filled with electrolyte solution Replace the fill solution and electrolyte Refer to Section 9 2 for details 10 4 7 Readings drift A Is the sample temperature changing Membrane permeability is a function of temperature The time constant for response to a temperature change is about 5 minutes Therefore the reading may drift for a while after a sudden temperature change Is the membrane clean For the sensor to work properly oxygen must diffuse freely through the membrane coating on the membrane will interfere with the passage of oxygen resulting in slow response Is the sensor in direct sunlight If the sensor is in direct sunlight during air calibration readings will drift as the sensor warms up Because the temperature reading lags the true temperature of the membrane calibrating th
29. note the temperature readings The measured temperature might not agree with the value in the table During sensor calibration an offset might have been applied to make the measured temperature agree with a standard thermometer The offset is also applied to the simulated resistance The controller is measuring tem perature 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 Q which corresponds to 10 0 C Assume the offset from the sensor calibration was 0 3 Because of the offset the analyzer calculates temperature using 103 6 The result is 9 2 C Now change the resistance to 107 8 which corresponds to 20 0 C The analyzer uses 107 5 Q to cal culate the temperature so the display reads 19 2 C Because the difference between the displayed tempera tures 10 0 C is the same as the difference between the simulated temperatures the analyzer is working correctly 60 SECTION 10 0 TROUBLESHOOTING RTD SENSE RTD RETURN FIGURE 10 2 Three Wire RTD Configuration Although only two wires are required to connect the RTD to the analyzer using a third and sometimes fourth wire allows the analyzer to correct for the resistance of the lead wires and for changes in the lead wire resistance with temperature simulates RTD RTD return RTD sense E R RTD in FIGURE 10 3 Simulati
30. sensor 3 Change temperature compensation from automatic to manual and enter a manual compensation temperature 4 View diagnostic variables Level 2 A level 2 user can 1 Do everything a level 1 user can do 2 Change alarm setpoints 3 Rerange the 4 20 mA outputs 4 Manually test both outputs and all four alarm relays Level 3 A level 3 user has access to every menu item Only a level 3 user can change passwords A person with no password can only view the main display 2 Press any key to enter the main menu Move the cursor to Program and press Enter F4 3 Move the cursor to Configure and press Enter F4 f Noise rejection d 4 Move cursor to Security and press Enter 4 Main sensor cal Exit Enter af 5 Use and keys to move through the list of items enter a password Z N press Edit F4 Use the arrow keys to enter a three digit password Press Lock all 0 Save F4 to store the value Lock all Until the user enters the lock password all he do is view Lock program 0 the main display Entering the lock all password allows the user access to all Level 1 functions Lock config 0 Lock program Entering the lock program password allows the user e access to all Level 2 functions U Edit IJ Lock config Entering the lock config password allows the user access to all Level 3 functions The analyzer will accept a higher le
31. the main menu Move the cursor to Program and press Enter F4 Move the cursor to Simulated tests and press Enter F4 Move the cursor to the desired output or alarm Both outputs and all four alarms can be tested Press Enter F4 A screen will appear warning that the output or alarm will change Press Cont F3 to continue Press Abort F1 to cancel the simula tion This screen appears when an output is being simulated To change the simulation current press Edit F4 Use the arrow keys to change the current to the desired value Press Test F4 then Esc F3 The simulated current will be generated for 10 minutes then the out put returns to normal operation To change the timeout to a different value see Section 5 4 To end the simulation at any time press Exit F1 This screen appears when an alarm is being simulated To change the state of the relay press Edit F4 Use the 4 or keys to change from open to closed Press Test F4 then Esc F3 The alarm will be simulated for 10 minutes then the alarm returns to normal operation To change the timeout to a different value see Section 5 4 To end the simulation at any time press Exit F1 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 4 CHOOSING DISPLAY OPTIONS 1 The 54eA analyzer can be used with other oxygen sensors manufactured by Rosemount Analytical as well as with chlorine monochloramine and ozone sensors The user must configu
32. the sample gener ate a small current called the residual current The analyzer compensates for the residual current by subtracting it from the measured current before converting the result to a dissolved oxygen value New sensors require zeroing before being placed in service and sensors should be zeroed whenever the electrolyte solution is replaced The recommended zero standard is 5 sodium sulfite in water although oxygen free nitrogen can also be used The purpose of the full scale standard is to establish the slope of the calibration curve Because the solubility of atmospheric oxygen in water as a function of temperature and barometric pressure is well known the natural choice for a full scale standard is air saturated water However air saturated water is difficult to prepare and use so the universal practice is to use air for calibration From the point of view of the oxygen sensor air and air sat urated water are identical The equivalence comes about because the sensor really measures the chemical poten tial of oxygen Chemical potential is the force that causes oxygen molecules to diffuse from the sample into the sensor where they can be measured It is also the force that causes oxygen molecules in air to dissolve in water and to continue to dissolve until the water is saturated with oxygen Once the water is saturated the chemical potential of oxygen in the two phases air and water is the same Oxygen sensors generate a current dir
33. to operate the air blast cleaner Relay 4 Sensor analyzer fault alarm Each relay has a dedicated LED on the front panel Relay Contacts Relays 1 3 Epoxy sealed form A contacts SPST normally open n N Relay 4 Epoxy sealed form C SPDT Resistive Inductive 115 Vac 5 0 Amps 3 0 Amps 230 Vac 5 0 Amps 1 5 Amps Ambient Temperature 0 to 50 C 32 to 1226 Analyzer can be operated between 20 and 60 4 to 140 F with some degradation in display quality Relative Humidity 95 maximum non condensing Temperature correction for membrane permeability automatic between 0 and 50 Calibration automatic air calibration or calibration against a standard instrument Pressure sensor range 113 to 862 mm Hg 150 to 1150 mbar is a registered trademark of General Electric 2Viton is a registered trademark of duPont de Nemours amp 3Tefion is a registered trademark of duPont de Nemours amp MODEL 00 03 04 SPECIFICATIONS COMPRESSOR FOR AIR BLAST CLEANER SYSTEM Enclosure Fiberglass reinforced polyester with poly ester cover NEMA 4x IP65 11 9 x 11 9 x 6 9 in 302 x 302 x 175 mm Compressor Oil less non lubricating piston and cylinder 1 12 HP permanent split capacitor motor with thermal overload protection Maximum continuous pressure 50 psig 446 kPa abs Operating pressure 20 psig 239 kPa abs Air hose 25 ft 7 6 m included with ABSH Ambient temperature
34. warning appears if the current process reading and the reading it is being changed to ie the reading from the standard instrument are appreciably different A B C Is the standard instrument properly zeroed and calibrated Are the standard and process sensor measuring the same sample Place the sensors as close together as possible Is the process sensor working properly Check the response of the process sensor in air and in sodium sul fite solution 10 4 5 Barometric pressure reading is too high or too low A Is the pressure inside the enclosure equal to ambient pressure The pressure sensor is inside the analyzer enclosure When cable glands are in place and the front panel is tightly closed the enclosure is moderately airtight Therefore as the air trapped in the enclosure heats or cools the pressure inside the enclosure may be different from ambient Open the front door to equalize the pressure If equalizing the pressure does not solve the problem the pressure sensor is out of calibration Calibrate the sensor against the local barometric pressure Be sure to use the actual barometric pressure Pressure some times called altimeter from a local airport or pressure from a weather forecasting service is usually corrected to sea level It is not the actual barometric pressure 57 MODEL 00 03 04 SECTION 10 0 TROUBLESHOOTING 10 4 6 Process readings are erratic A B m Readings are often erratic when a
35. 1 0 SPECIFICATIONS sensor cable air hose maintenance bracket pipe boom supplied by customer power cable FIGURE 1 1 Suggested arrangement of handrail mounting assembly maintenance clamp air compressor enclosure and 54eA analyzer WHEN INCH AND METRIC DIMS ARE GIVEN e MILLIMETER 5 INCH TYP m L 50 Kite Bi Y 1875 595 21N PIPE SUPPL IED BY OTHERS 144 ANN Nets L U BOLT WITH NUTS AND WASHERS FRONT VIEW D 9 525 SIDE VIEW FOR 21N PIPE 375 2 PLACES 4 MOUNTING HOLES MOUNTING BRACKET FIGURE 1 2 Analyzer dimensions MODEL 00 03 04 SECTION 1 0 SPECIFICATIONS WHEN INCH AND METRIC DIMS ARE GIVEN e INCH MILLIMETER a 1 inch MNPT D ROSEMOUNT BLAST be SENSOR OC SYSTEM d Electrolyte fill plug Smooth retainer Nc P 14 26 362 1 FIGURE 1 4 Standard sensor with FIGURE 1 3 Enclosure dimensions integral cable SE AIR DELIVERY SENSOR CABLE TUBING AIR DELIVERY TUBING 1 1 2 PVC PIPE SCH 80 1 1 2 PVC PIPE SCH 80 SUPPLIED BY OTHERS ia BY OTHERS AIR CHECK VALVE DISSOLVED OXYGEN SENSOR AIR TUBING QUICK DISCONNEC
36. A or to the value programmed in Section 5 5 See Section 10 2 for an explanation of fault messages and suggested corrective actions The analyzer also displays error and warning messages if a calibration is seriously in error Refer to the section below for assistance Each section also contains hints for correcting other measurement and calibration problems Measurement Section Temperature Dissolved oxygen For troubleshooting not related to measurement problems see Section 10 5 To view diagnostic variables go to the main display and press any key Move the cursor to Diagnostic variables and press Enter F4 Use the 4 or W key to move up or down the list 10 2 TROUBLESHOOTING WHEN A FAULT MESSAGE IS SHOWING Fault message See Section High input current Check sensor zero Temp error low Temp error high temperature greater than 130 Sense line open RTD sense line is open instrument needs factory calibration Failure eeprom write verify error has occurred 54 MODEL 00 03 04 SECTION 10 0 TROUBLESHOOTING 10 2 1 High input current Excessive sensor current implies that the oxygen sensor is miswired or the sensor has failed Verify that wiring is correct including connections through a junction box See Section 3 3 If wiring is correct try replacing the sen sor 105 2 2 Check sensor zero The sensor current was extremely high when the sensor was zeroed Typical zero current for an oxygen sensor is less than
37. D Return sensor and cable are available Figure 3 6 5 Receive coman 3 RTO Sense romp 2 g shows how to wire this sensor to the analyzer i cher E H 1 0 3 Anodi c 02 11 ive e m ER T84 Beran HART DWG NO 40054 03 FIGURE 3 4 Wiring Label DWG NO DWG NO 40499A23 A 40499 24 CLEAR NOT NOT USED USED WHITE RTD RETURN RTD RETURN WHITE RED RTD SENSE RTD SENSE RED RTD IN RTD IN CLEAR S CLEAR SHIELD SHIELD CLEAR ORANGE CATHODE CATHODE OPTIMUM EMI RFI GRAY ANODE STANDARD CABLE HITE 1 ANODE CABLE FIGURE 3 5 Oxygen sensor FIGURE 3 6 Oxygen sensor with optimum with standard cable EMI RFI cable or Variopol cable 16 MODEL 00 03 04 SECTION 4 0 DISPLAY AND OPERATION SECTION 4 0 DISPLAY AND OPERATION 4 1 DISPLAY Figure 4 1 shows the main display 1 00 ppm 12 00 mA 3200 nA 26 2 0 50 gt FIGURE 4 1 Main Display Screen The concentration of oxygen is displayed continuously in large numerals The temperature and output current are displayed on the second line The third line can be config ured by the user In the example the third line shows the alarm 1 setpoint a
38. Enter 4 Output setpoints Simulated tests Configure g Exit b 4 Move the cursor to Alarms and press Enter F4 Outputs E Alarms A Exit Bey G N 5 Nine menu headers relate to alarms Alarms 1 2 and 3 each have a Alarm 1 control control header and a setup header Alarm 4 has only a setup header The eighth menu header is for configuring the feed limit timer and the Alarm 1 setup ninth menu header is for configuring the interval timer Alarm 2 control NOTE The 54 analyzer be ordered with optional TPC control df feature The version of the 54eA analyzer provided with the DO 03 04 does not have control Although the control head er appears in this screen it is not activated To access a header move the cursor to the desired header and press Enter F4 Er method B 5 Alarm Control Settings a Move cursor to the desired output control header Press Enter Control mode F4 b With the cursor on Activation method press Enter F4 9 Exit Enter J 31 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 6 CHANGING ALARM PARAMETERS continued TOTAA Process 7 Alarm 1 control Alarm 1 setup Alarm 2 control A Exit Edit 2 g Exit Low Setpoint 0 000 ppm Hysteresis 0 000 ppm M Exit SE alarm deactivates low alarm setpoint E o
39. Instruction Manual 51 DO 03 04 rev C October 2004 Model DO 03 04 Dissolved Oxygen Measurement System with Air Blast Cleaner e eo Se vm Fees 4 e P e TU p Sen lk ien mail ira Sy aaa ae JE SC ROSEMOUNT e Analytical EMERSON Process Management ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING Rosemount Analytical designs manufactures and tests its products to meet many national and international standards Because these instru ments are sophisticated technical products you must properly install use and maintain them to ensure they continue to operate within their normal specifications The following instructions must be adhered to and integrat ed into your safety program when installing using and maintaining Rosemount Analytical products Failure to follow the proper instructions may cause any one of the following situations to occur Loss of life per sonal injury property damage damage to this instrument and warranty invalidation Read all instructions prior to installing operating and servicing the prod uct If this Instruction Manual is not the correct manual telephone 1 800 654 7768 and the requested manual will be provided Save this Instruction Manual for future reference If you do not understand any of the instructions contact your Rosemount representative for clarification Follow all warnings cautions and instructions
40. Options 27 5 5 Changing Output Parameiers nennen eene 29 5 6 Changing Alarm Parameters nennen enne 31 5 7 Temperature Compensation and Temperature Untts ne 35 5 8 Noise Reduction iita N 36 5 9 Barometric Pressure ence e tede SEENEN 37 5 10 Main Sensor Calibration Parameters ees 38 5 11 M 39 5 12 Analyzer Mode Priority recti eec i EERE 40 6 0 CALIBRATION 41 6 1 Introdut ria oti arte dette Re eee iquat eee vada 41 6 2 Temperature GalibratiOn e e Pret dal he tg Rad 42 7 0 CALIBRATION DISSOLVED 43 7 1 cm 43 7 2 Zeroing THE Sensor ui oec bit etu d exec c di deca ER 44 7 3 Calibrating the Sensor in Air eese eee dne 45 7 4 Calibrating the Sensor Against a Standard 47 7 5 Calibrating Barometric Pressure 48 8 0 CALIBRATION CURRENT 49 8 1 lu goe e de 49 8 2 Tamming Ee EC 49 MODEL 00 03 04 TABLE OF CONTENTS TABLE OF CONTENTS CONTINUED Section Title Page 9 0 MAINTENANGE SE ciens 50 9
41. SECTION 5 0 SOFTWARE CONFIGURATION 5 5 CHANGING OUTPUT PARAMETERS continued Output 1 Control Output 1 Setup Output 2 Control Exit EDS TERE 4 20 mA Dampen 0 sec Hold Last Value Exit z Edit 7 Output 2 control Output 2 setup Hold feature setup Exit SE 30 7 Output setup for normal outputs a Move the cursor to the desired output setup and press Enter F4 b Use and V arrow keys to move the cursor to the desired parameter Press Edit F4 Use the arrow keys to change the set ting to the desired value and press Save F4 to store the value Range Choose 4 20 mA or 0 20 mA Dampen Dampening averages the output current thus smooth ing out a noisy reading Higher values provide more smoothing but increase the response time of the output Hold and Fixed Hold If the analyzer is placed in hold the out puts will either remain at the last value or go to a fixed value selected by the user The fixed value must be between 0 and 22 00 mA Fault If the analyzer detects a fault the output will signal the fault by going to a user selected current between 0 and 22 00 mA For allowed values see Table 5 1 8 Hold setup a Move the cursor to Hold feature setup and press Enter F4 b Press Edit F4 Use the to scroll through the choices Disable feature Enable feature and 20 min timeout If
42. T DOUBLE O RING AIRJET SPRAY NOZZLE Y eres AIRJET SPRAY NOZZLE FIGURE 1 5 Air blast washer head MODEL 00 03 04 SECTION 1 0 SPECIFICATIONS ORDERING INFORMATION The Model DO 03 04 is a complete system for the determination of oxygen in wastewater aeration basins It consists of a 54eA analyzer a 499ADO 54 oxygen sensor an air blast washer head with air compressor and hose and a handrail mounting bracket All hardware necessary to mount the analyzer and the air compressor enclosure on a handrail is provided Cable gland fittings for the analyzer are also supplied Three replacement membranes and a bottle of electrolyte solution are shipped with the sensor Pipe boom is supplied by customer MODEL DO DISSOLVED OXYGEN MEASURING SYSTEM WITH AIR BLAST CLEANER Description Dissolved Oxygen Measuring System Power required selection 115 Vac 60 Hz or 100 Vac 50 60 Hz 220 Vac 50 Hz ACCESSORIES FOR 54eA ANALYZER Part DESCRIPTION 9240048 00 Tag stainless steel specify marking CONSUMABLES FOR SENSOR DESCRIPTION 23502 00 Membrane replacement kit with O ring qty 3 9210264 Amperometric sensor fill solution 1 4 oz 120 mL Customers using plant compressed air should order the following items in place of Model 03 04 54 01 Model 54eA analyzer Mounting bracket for Model 54e pipe wall Cable glands kit for Model 54e qty 5 Model 499ADO ox
43. The following is the procedure for returning for repair instruments that are no longer under warranty 1 Call Rosemount Analytical for authorization 2 Supply the purchase order number and make sure to provide the name and telephone number of the individ ual to be contacted should additional information be needed 3 Do Steps 3 and 4 of Section 11 2 NOTE Consult the factory for additional information regarding service or repair 61 RETURN OF MATERIALS REQUEST IMPORTANT This form must be completed to ensure expedient factory service FROM RETURN BILL TO amso4n CUSTOMER USER MUST SUBMIT MATERIAL SAFETY SHEET MSDS OR COMPLETE STREAM COMPOSITION AND OR LETTER CERTIFYING THE MATERIALS HAVE BEEN DISINFECTED AND OR DETOXIFIED WHEN RETURNING ANY PROD UCT SAMPLE OR MATERIAL THAT HAVE BEEN EXPOSED OR USED IN AN ENVIRONMENT OR PROCESS THAT CON TAINS A HAZARDOUS MATERIAL ANY OF THE ABOVE THAT IS SUBMITTED TO ROSEMOUNT ANALYTICAL WITHOUT THE MSDS WILL BE RETURNED TO SENDER C O D FOR THE SAFETY AND HEALTH OF OUR EMPLOYEES WE THANK YOU IN ADVANCE FOR COMPLIANCE TO THIS SUBJECT mo 4oz amozmo SENSOR OR CIRCUIT BOARD ONLY Please reference where from in MODEL SER NO Column 1 PART NO 1 MODEL PART NO 2 MODEL PART NO 3 MODEL PART NO 4 MODEL PLEASE CHECK ONE REPAIR AND CALIBRATE DEMO EQUIPMENT NO EVALUATION OTHER EXPLAIN REPLACEMENT REQUIRED DESCRIPTION OF MALFUNCTION
44. XYGEN To check the performance of the controller use a decade box to simulate the current from the oxygen sensor A Disconnect the anode and cathode leads from terminals 1 and 2 on TB3 and connect a decade box as shown in Figure 10 1 It is not necessary to disconnect the RTD leads B Set the decade box to the resistance shown in the table Sensor Polarizing Voltage Expected current 499ADO 675 mV 20 uA C Note the sensor current To view the sensor current from the main display press any key to enter the main menu Move the TBS cursor to Diagnostics and press Enter F4 The sensor cur rent is the second line in the display Note the units uA is RTD return g microamps nA is nanoamps RTD sense ES D Change decade box resistance and verify that the correct current is shown Calculate current from the equation RTD in EN voltage mV shields EX resistance cathode cr simulates ES sensor anode current uA FIGURE 10 1 Simulate Dissolved Oxygen 59 MODEL 00 03 04 10 7 SIMULATING TEMPERATURE 10 7 1 General The 54eA analyzer accepts a Pt100 RTD The Pt100 RTD is in a three wire configuration See Figure 10 2 10 7 2 Simulating temperature To simulate the temperature input wire a decade box to the analyzer or junction box as shown in Figure 10 3 To check the accuracy of the temperature measurement set the resistor simulating the RTD to the values indicat ed in the table and
45. a standard instrument For oxygen sensors installed in aera tion basins in waste treatment plants calibration against a second instrument is often preferred For an accurate calibration be sure that 1 The standard instrument has been zeroed and calibrated against water saturated air following the manufac turer s instructions 2 The standard sensor is immersed in the liquid as close to the process sensor as possible 3 Adequate time is allowed for the standard sensor to stabilize before calibrating the process instrument NS 4 From the main display press any key to obtain the main menu With Calibrate main sensor the cursor on Calibrate press Enter F4 Zero main sensor bd If Hold was enabled in Section 5 5 the hold screen will appear Adjust temperature To activate hold refer to Section 5 5 step 9 A Exit ae Press Enter F4 5 The screen at left appears Press the key once to move the cursor to Calibrate in process Then press Enter F4 am Calibrate in air Calibrate in process Barometric pressure M Exit Enter X 6 Press Cont F3 Wait flashes until the sensor is stabilized 0 32 If the analyzer appears locked the reading is not stable enough Increase the amount the concentration is permitted to vary or Stabilizing Wait decrease the stabilization time See Section 5 10 Repeat the calibra GR t
46. alue input by the operator mA for current on or off for a relay 40 MODEL 00 03 04 SECTION 6 0 CALIBRATION TEMPERATURE SECTION 6 0 CALIBRATION TEMPERATURE 6 1 INTRODUCTION The Model 499ADO sensor is a membrane covered amperometric sensor As the sensor operates oxygen diffus es through the membrane and is consumed at an electrode immediately behind the membrane The reaction pro duces a current that depends on the rate at which oxygen diffuses through the membrane The diffusion rate in turn depends on the concentration of oxygen and how easily it passes through the membrane the membrane perme ability Because the membrane permeability is a function of temperature the sensor current will change if the tem perature changes To correct for changes in sensor current caused by temperature the analyzer automatically applies a membrane permeability correction that converts the sensor current to the value at 25 C The change is about 3 C at 25 C so a 1 C error in temperature produces about a 3 error in the reading Temperature plays an additional role in oxygen measurements Oxygen sensors are calibrated by exposing them to water saturated air which from the point of view of the sensor is equivalent to water saturated with atmospher ic oxygen see Section 7 0 for more information During calibration the analyzer calculates the solubility of atmos pheric oxygen in water using the following steps First the analyzer me
47. asures the temperature From the temper ature the analyzer calculates the vapor pressure of water and using the barometric pressure calculates the par tial pressure of atmospheric oxygen Once the analyzer knows the partial pressure it calculates the equilibrium solubility of oxygen in water using a temperature dependent factor called the Bunsen coefficient Overall a 1 C error in the temperature measurement produces about a 2 error in the solubility calculated during calibration and about the same error in subsequent measurements Without calibration the accuracy of the temperature measurement is about 0 4 C Calibrate the controller if 1 0 4 accuracy is not acceptable 2 the temperature measurement is suspected of being in error Calibrate temperature by making the controller reading match the temperature measured with a standard thermometer 41 MODEL 00 03 04 SECTION 6 0 CALIBRATION TEMPERATURE 6 2 TEMPERATURE CALIBRATION Place the sensor and a standard thermometer in the process liquid 1 Check the analyzer temperature reading main display to make sure the sensor has stabilized Compare the analyzer temperature with the standard thermometer The readings should differ by at most 1 If the read ings differ by a greater amount refer to Section 15 3 Go to the next step if the reading requires adjustment 1 Zero main sensor Adjust temperature Output trim G MEE 25 1
48. be as much as 5 different from ambient pressure 2 From the main display press any key With the cursor on Calibrate press Enter F4 z gt 3 Press Enter F4 to select Calibrate main sensor Calibrate main sensor Zero main sensor Adjust temperature Exit Enter 4 Press the key twice to move the cursor to Barometric pressure emm m 5 Calibrate in air Press Enter F4 Calibrate in process Barometric pressure S Exit Enter gt 5 Press Edit F4 Use the arrow keys to change the pressure reading 103 mm Hg to the desired value Press Save F4 to store the value SE 760 6 Press Exit F1 four times to return to the main display Exit Edit 48 MODEL 00 03 04 SECTION 8 0 CALIBRATION CURRENT OUTPUTS SECTION 8 0 CALIBRATION CURRENT OUTPUTS 8 1 INTRODUCTION Although the analyzer outputs are calibrated at the factory they can be trimmed in the field to match the reading from a standard current meter Both the low output 0 or 4 mA and the high output 20 mA can be trimmed 8 2 TRIMMING THE OUTPUTS Adjust temperature Calibrate pH Output trim Lk Exit Enter CAUTION Current outputs may be affected Exit Enter P point 1 Meter 4 00 mA Expected 4 00 mA Simulating outputt Abort Cont M Trim output
49. costs of dismantling reinstallation and freight and the time and expenses of Seller s person nel for site travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Seller Goods repaired and parts replaced during the warranty period shall be in warranty for the remainder of the original warranty peri od or ninety 90 days whichever is longer This limited warranty is the only warranty made by Seller and can be amended only in a writing signed by an authorized representative of Seller Except as otherwise expressly provided in the Agreement THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND EXPRESS OR IMPLIED AS TO MERCHANTABILITY FIT NESS FOR PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES RETURN OF MATERIAL Material returned for repair whether in or out of warranty should be shipped prepaid to Emerson Process Management Liquid Division 2400 Barranca Parkway Irvine CA 92606 The shipping container should be marked Return for Repair Model The returned material should be accompanied by a letter of transmittal which should include the following information make a copy of the Return of Materials Request found on the last page of the Manual and provide the following thereon Location type of service and length of time of service of the device Description of the faulty operation of the device and the circumstances of the failure Name and tel
50. ding og str mstyrke som sikkerhed for vedvarende beskyttelse mod brandfare Sikringerne er placeret under denne p skrift ATTENTION M DANGER KAN ONDER SPANNING STAAN POSSIBILITE DE HAUTE TENSION Raccorder le tube la masse m tallique d une entretoise ou du coffret Utiliser des raccords et des bouchons tanches ininflammables afin de preserver classification du boitier Der Analysator ist vorschriftsmaessig zu erden En cas de d montage de ce capot cu des fusibles Verwijderen van zekering of dit deksel kan dit Risques de Blessures graves ou de mort leiden tot ernstig of dodelijk letsel AA VOORZICHTIG A ATTENTION Voor duurzame bescherming tegen brand uitsluitend zekeringen gebruiken met aangegeven nominale spannings en stroomwaarden De zekeringen bevinden zich onder dit deksel Afin d assurer une protection permanente contre le feu ne remplacer les fusibles que par des mod les quivalents en tension et en courant Les fusibles se trouvent derriere cette plaquette GEFAEHRLICHE ELEK TRISCHE SPANNUNG Ist die Schutzabdeckung ader die Sicherung entfernt so koennen Geraet ernsthafte oder toedliche SPENNING KAN VJERE TIL STEDE nar sikringen eller dette deksiet fj rnes og kan fare til alvorlige skader eller d dsulykker Um die Schutzart des Geraetes sicherzustellen ist es mit den ATTENTION entsprechenden For at beskyttelse mot a
51. e sensor in direct sunlight may introduce an error Is the sample flow within the recommended range Gradual loss of sample flow will cause downward drift 15 the sensor new or has it been recently serviced New or rebuilt sensors may require several hours to sta bilize 10 4 8 Sensor does not respond to changes in oxygen level A B C If readings are being compared with a portable laboratory instrument verify that the laboratory instrument is working Is the membrane clean Clean the membrane and replace it if necessary Also increase the frequency and duration of the air blast Check that the holes at the base of the cathode stem are open Use a straightened paper clip to clear blockages Replace the electrolyte solution Replace the sensor 10 4 9 Oxygen readings are too low A 58 Low readings can be caused by zeroing the sensor before the residual current has reached a stable minimum value Residual current is the current the sensor generates even when no oxygen is in the sample Because the residual current is subtracted from subsequent measured currents zeroing before the current is a mini mum can lead to low results Example the true residual zero current for a 499ADO sensor is 0 05 uA and the sensitivity based on cali bration in water saturated air is 2 35 Assume the measured current is 2 00 nA The true concentra tion is 2 00 0 05 2 35 or 0 83 ppm If the sensor was zeroed prematurely whe
52. e tensioned membrane in place Replacing the electrolyte solution takes only minutes The Model DO 03 04 includes the rugged easy to use Model 54eA analyzer The analyzer features two fully pro grammable 4 20 mA outputs and three fully programmable alarm relays The backlit three line display allows the user to read oxygen levels at a glance The analyzer permits both air calibration and calibration against a labora tory instrument Air calibration is completely automatic All the user does is expose the sensor to water saturated air and press a few buttons The Air Blast Sensor Cleaner which includes the washer head and air compressor keeps the sensor membrane clean helping ensure reliable trouble free oxygen measurements and reducing sensor cleaning maintenance to as little as every three months At programmed intervals the air blast cleaner blows a stream of air across the membrane to clear bio film from on the membrane The frequency and duration of the air blast is programmable from the 54eA analyzer The photograph shows a sensor after nine weeks in an aeration basin The cathode is clearly visible under the membrane A 60 second air blast every eight hours is keeping the membrane clean Plant service air can be used in place of the air compressor The 54eA analyzer relay is then used to operate a solenoid valve MODEL 00 03 04 SPECIFICATIONS 499ADO 54 SENSOR Range 0 to 20 ppm mg L Wetted parts Viton EPDM Teflon
53. ectly proportional to the rate at which oxygen molecules diffuse through a membrane stretched over the end of the sensor The diffusion rate depends on the difference in chemical poten tial between oxygen in the sensor and oxygen in the sample An electrochemical reaction which destroys any oxy gen molecules entering the sensor keeps the concentration and the chemical potential of oxygen inside the sen sor equal to zero Therefore the chemical potential of oxygen in the sample alone determines the diffusion rate and the sensor current When the sensor is calibrated the chemical potential of oxygen in the standard determines the sensor current Whether the sensor is calibrated in air or air saturated water is immaterial The chemical potential of oxygen is the same in either phase Normally to make the calculation of solubility in common units like ppm DO simpler it is convenient to use water saturated air for calibration Automatic air calibration is standard The user simply exposes the sensor to water saturated air The analyzer monitors the sensor current When the current is stable the analyzer stores the current and measures the baro metric pressure and temperature The temperature element is part of the dissolved oxygen sensor The pressure sensor is inside the analyzer From the temperature the analyzer calculates the saturation vapor pressure of water Next it calculates the pressure of dry air by subtracting the vapor pressure from
54. en Disconnect the sense and return leads and measure the resistance between them It should be less than 50 If the sense line is open replace the sensor as soon as possible The analyzer can be operated with the sense line open The measurement will be less accurate because the ana lyzer can no longer compensate for lead wire resistance However if the sensor is to be used at approximately constant ambient temperature the lead wire resistance error can be eliminated by calibrating the sensor at the measurement temperature Errors caused by changes in resistance with changes in ambient temperature cannot be eliminated To make the error message disappear connect the RTD sense and return terminal with a jumper 10 2 5 Failure factory and Failure eeprom Turn the power off wait about 30 sec then turn the power back on If the error message does not clear call the factory In the United States call 800 854 8257 Outside the United States call 949 757 8500 55 MODEL 00 03 04 SECTION 10 0 TROUBLESHOOTING 10 3 TROUBLESHOOTING WHEN NO FAULT MESSAGE IS SHOWING TEMPERATURE 10 3 1 Temperature measured by standard was more than 1 C different from analyzer A ls standard thermometer RTD or thermistor accurate General purpose liquid in glass thermometers par ticularly ones that have been mistreated can have surprisingly large errors B Is the temperature element in the sensor completely submerged in the liquid C Is the sta
55. ephone number of the person to contact if there are questions about the returned material Statement as to whether warranty or non warranty service is requested Complete shipping instructions for return of the material Adherence to these procedures will expedite handling of the returned material and will prevent unnecessary additional charges for inspection and testing to determine the problem with the device If the material is returned for out of warranty repairs a purchase order for repairs should be enclosed The right people the right answers b d right now ROSEMOUNT ANALYTICAL CUSTOMER SUPPORT CENTER 1 800 854 8257 Emerson Process Management Liquid Division 2400 Barranca Parkway Irvine CA 92606 USA Tel 949 757 8500 Fax 949 474 7250 http www raihome com Rosemount Analytical Inc 2005 ON LINE ORDERING NOW AVAILABLE ON OUR WEB SITE http www raihome com Specifications subject to change without notice AE eo aN Credit Cards for U S Purchases Only 5 VISA Maste Card WE ED E 2 lt EMERSON Process Management
56. equalizing port See Figure 9 1 NOTE Do not use a sharp probe It will puncture the bladder and destroy the sensor Gently press the probe against the bladder several times to force liquid through the holes at the 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 Place a drop of electrolyte solution on the cathode then place the membrane assembly over the cathode Screw the membrane retainer in place The sensor may require several hours operating at the polarizing voltage to equilibrate after the electrolyte solution has been replenished NOTE If the membrane and electrolyte solution were replaced check the sensor performance before reassembling the sensor and washer head assembly To zero the sensor refer to Section 7 2 To perform an air calibration refer to Section 7 3 51 MODEL 00 03 04 SECTION 9 0 MAINTENANCE PRESSURE EQUALIZING PORT CATHODE O RING ELECTROLYTE FILL PLUG MEMBRANE ASSEMBLY WRAP WITH PIPE TAPE SENSOR CABLE SMOOTH RETAINER CAP FIGURE 9 1 Sensor Parts SPARE PARTS 33523 00 Electrolyte Fill Plug 9550094 O Ring Viton 2 014 24057 00 Membrane Retainer smooth cap 23501 00 Dissolved Oxygen Membrane Assembly includes one membrane assembly and one O ring 23502 00 Dissolved Oxygen Membrane Ki
57. ey is pressed at which time the analyzer returns to normal operation and the feed limit clock starts again NOTE Pressing Ack F2 acknowledges all conditions that turn on the red LED If another event occurs after F2 is pressed F2 must be pressed again to acknowledge the new event 33 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 6 CHANGING ALARM PARAMETERS continued 11 Interval timer setup Alarm 1 2 or 3 can be used as an interval timer The selected relay will open and close at time intervals programmed by the user The interval timer is useful for automatic cleaning of sensors NOTE The alarm relay used for the interval timer cannot be used for other purposes When a timer sequence is occurring both current outputs are placed in hold even if hold was not enabled and the other two alarms will be placed in their default states a From the menu header screen step 6 move the cursor to Alarm 4 setup Interval timer Feed limit timer Interval timer L Exit SR b With the cursor on Interval timer press Enter F4 Use the V N Timer Disable key to scroll through the selections Use the arrow keys to 5 change settings Press Save F4 to store Timer Time activated We Refer to the diagram for definition of terms interval repeats on Interval 24 0 hr time off time and recovery Exit Edit 2 oft activated t
58. f Disable alarm 1 alarm 2 or alarm 3 0 to 10 800 sec Disable alarm 1 alarm 2 or alarm 3 0 to 999 9 hr 1 to 60 0 to 2999 sec 0 to 2999 sec 0 to 999 sec SECTION 5 0 SOFTWARE CONFIGURATION FACTORY SETTINGS Oxygen Normal 4 20 mA 0 sec Hold last value 21 mA 22 mA Temperature Normal See output 1 Disable Oxygen Normal High 0 ppm 0 ppb 096 0 1 0 sec None Oxygen Normal Low Fault Disable 600 sec Disable 24 0 hr 1 120 sec 1 sec 600 sec Continued on the following page MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION TABLE 5 1 Program Settings List continued ITEM CHOICES FACTORY SETTINGS CONFIGURE continued D Temperature compensation Section 5 7 1 Temperature compensation Auto or manual 2 Manual temperature 15 to 130 C E Noise Reduction section 5 8 Noise rejection 50 or 60 Hz Barometric Pressure Section 5 9 Barometric pressure Auto or manual Auto Barometric pressure manual 0 4 1 2 atm or equivalent units 1 00 atm Barometric pressure units mm Hg in Hg bar kPa mm Hg Main sensor calibration Section 5 10 Stabilize reading a oxygen ppm 0 to 20 ppm b oxygen saturation 0 to 200 Stabilize time 0 30 sec Sensor zero stabilization value Salinity parts per thousand 0 0 99 9 9 oo Security Section 5 11 Lock all 000 999 000 disables Lock program 000 999 000 disables Lock configuration 000 999 000
59. gram and press Enter F4 Move the cursor to Configure and press Enter F4 Move the cursor to Main sensor cal and press Enter F4 Use the and keys to move through the list of items To make a change press Edit F4 Use the arrow keys to change settings to the desired value and press Save F4 For allowed ranges see Table 5 1 The choices depend on the measurement being made Stabilize and Stabilize time For the analyzer to accept calibration data the concentration must remain within a specified range for a specified period of time The default values are 0 05 ppm and 10 sec onds Using a small stabilize value and a long stabilize time is the best protection against calibration while a reading is still changing Salinity Salinity is used with oxygen measurements only The solu bility of oxygen in water depends on the concentration of dissolved salts in the water Increasing the concentration decreases the solubil ity If the salt concentration is greater than about 1000 ppm the accu racy of the measurement can be improved by applying a salinity cor rection Enter the salinity as parts per thousand 9 oo One percent is ten parts per thousand MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 11 SECURITY 1 The analyzer can be programmed to require a password for access to menus There are three levels Level 1 Alevel 1 user can 1 Zero and calibrate the oxygen sensor 2 Calibrate the barometric pressure
60. ime in sec relay deactivated recovery sec interval h two repeats per cycle FIGURE 5 4 Interval Timer The user must determine the optimum cleaning frequency and duration Operating the air blast cleaner for 60 seconds every eight 8 hours is a good starting point Allow a 90 second recov ery time 34 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 7 TEMPERATURE COMPENSATION AND TEMPERATURE UNITS 1 Refer to Section 6 1 for a discussion of the ways in which temperature affects dissolved oxygen measurement Temperature Noise rejection e gt Lk Exit Enter Ce Auto Temp units C Temp comp Manual Temp units C 2506 L Exit Edit 2 Exit Edit 2 Press any key to enter the main menu Move the cursor to Program and press Enter F4 Move the cursor to Configure and press Enter F4 Move the cursor to Temperature and press Enter F4 Use the ah and keys to move through the list of items To make a change press Edit F4 Use the arrow keys to change settings to the desired value Press Save F4 to store changes Auto In automatic temperature compensation the analyzer meas ures the temperature using an RTD resistance temperature device in the sensor The analyzer then uses the measured temperature to calculate the membrane permeability correction and ox
61. ion To proceed with the calibration as is press Cont Bees Cont P b 7 Once the reading is stable the screen at left appears Press Edit F4 Use the arrow keys to change the concentration in the second m line of the display to the desired value Press Save F4 to store the value Calibrate 8 32 ppm 8 Press Exit F1 four times to return to the main display A Exit Edit 2 If Hold was activated during calibration Hold Mode Activated will continue to flash in the main display Return the sensor to normal and deactivate Hold Refer to Section 5 5 step 9 47 MODEL 00 03 04 SECTION 7 0 CALIBRATION DISSOLVED OXYGEN 7 5 CALIBRATING BAROMETRIC PRESSURE 1 If the barometric pressure measured by the analyzer does not agree with the local barometric pressure cali brate the pressure sensor A pressure error of 3 mm Hg introduces an error of about 0 5 in the final meas urement When calibrating the pressure reading be sure to use the actual barometric pressure Weather fore casters and airports usually report barometric pressure corrected to sea level they do not report the acutal pressure It is good practice to open the enclosure door before starting a barometric pressure calibration When gland fittings are used the analyzer enclosure is moderately airtight As the analyzer enclosure heats or cools the pressure of the air trapped inside the enclosure may
62. k disconnect for the air hose should be easily accessible Disconnect the air hose by pressing on the metal tab of the fitting and pulling the hose away from the base Unscrew the base from the sensor DO NOT LOSE THE O RING THAT SEALS THE SENSOR TO BOTTOM ASSEMBLY 50 MODEL 00 03 04 SECTION 9 0 MAINTENANCE To reassemble the sensor and air blast cleaner 1 2 Inspect the sensor O ring If it is cracked or cut replace it Clean the O ring and slide it over the end of the sensor until it rests against the lower edge of the bottom facing threads Clean and dry the bottom portion of the sensor washer assembly Inspect the surface that the sensor O ring seals against to verify that it is clean and smooth Inspect the dual O rings to ensure that they are not cracked or cut If the O rings appear to be damaged replace them NOTE The sensor O ring and the two washer head O rings are available in PN 24053 00 Be sure the O ring sealing surfaces in the upper portion of the sensor washer head assembly are clean and smooth Reconnect the air hose Lubricate the O rings with a small amount of grease Push the bottom part of the sensor washer head back into the upper portion of the assembly Replace and tighten the set screw To replace the electrolyte solution and membrane CAUTION 1 10 11 12 Unscrew the membrane retainer and remove the membrane assembly Fill solution may cause and O ring See Figure 9 1 i
63. marked on and supplied with the product Inform and educate your personnel in the proper installation operation and maintenance of the product Install your equipment as specified in the Installation Instructions of the appropriate Instruction 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 oper ate update program and maintain the product When replacement parts are required ensure that qualified people use replacement parts specified by Rosemount Unauthorized parts and procedures can affect the product s performance and place the safe operation of your process at risk Look alike substitutions may result in fire electrical hazards or improper operation Ensure that all equipment doors are closed and protective covers are in place except when maintenance is being performed by qualified per Sons to prevent electrical shock and personal injury WARNING ELECTRICAL SHOCK HAZARD Making cable connections to and servicing this instru ment require access to shock hazard level voltages which can cause death or serious injury therefore disconnect all hazardous voltage before accessing the electronics Relay contacts made to separate power sources must be disconnected before servicing Electrical installation must be in accordance with the National Electrical Code ANSI NFPA 70 and or any othe
64. n the current was 0 2 uA the measured concentration will be 2 00 0 2 2 35 or 0 77 ppm The error is 7 296 Suppose the measured cur rent is 5 00 uA The true concentration is 2 11 ppm and the measured concentration is 2 05 ppm The error is now 3 396 The absolute difference between the readings remains the same 0 06 ppm Sensor response depends on flow If the flow is too low readings will be low and flow sensitive Move the sen sor to an area in the aeration basin where the flow or agitation is greater MODEL 00 03 04 SECTION 10 0 TROUBLESHOOTING 10 5 TROUBLESHOOTING NOT RELATED TO MEASUREMENT PROBLEMS Problem Action Display segments missing Replace display board Alarm relays are chattering 1 Check alarm setpoints 2 Increase hysteresis time delay settings see Section 5 6 Incorrect current output 1 Verify that output load is less than 600 2 For minor errors trim outputs see Section 8 0 3 Replace power supply board Display too light or too dark Change contrast see Section 5 4 Level 1 2 or 3 security Lock shown in displa Controller has password protection see Section 5 11 Hold mode activated showing in displa Controller is in hold see Section 5 5 steps 8 and 9 Simulating output 1 or 2 showing in displa Controller is simulating outputs see Section 5 3 Simulating alarm 1 2 3 or 4 showing in display Controller is simulating alarms see Section 5 3 10 6 SIMULATING INPUTS DISSOLVED O
65. nce of error when configuring the analyzer the first time enter settings in the order shown in the table TABLE 5 1 Program Settings List ITEM SETPOINTS A Alarms Section 5 1 1 Alarm 1 low action a if oxygen ppm b if oxygen saturation c if temperature 2 Alarm 2 high action a if oxygen ppm b if oxygen saturation c if temperature 3 Alarm 3 B Outputs Section 5 2 and 5 3 1 Output 1 or 2 4 mA setting a if oxygen ppm b if oxygen saturation c if temperature 2 Output 1 or 2 20 mA setting a if oxygen ppm b if oxygen saturation c if temperature CONFIGURE A Display options Section 5 4 Measurement Sensor Oxygen only Units Oxygen only Temperature units Output 1 Output 2 Language Main display left Main display right 10 Display contrast 11 Test timeout 12 Timeout value Continued on the following page CHOICES 99 to 99 ppm 0 to 200 5 to 130 C 99 to 99 ppm 0 to 200 5 to 130 C See alarm 2 99 to 99 ppm 0 to 200 5 to 130 C 99 to 99 ppm 0 to 200 5 to 130 C Oxygen ozone free chlorine total chlorine Rosemount standard Rosemount biopharm or other steam sterilizable ppm ppb saturation C or F mA or of full scale mA or of full scale English Francais Espafiol Deutsch Italiano See section 5 5 See section 5 5 00 99 darkest On or off 1 to 60 min FACTORY SETTINGS 0 ppm 0 0
66. nd the sensor current 4 2 KEY FUNCTIONS AND CONTROL The keys labeled F1 F2 F3 and F4 are multi function The function appears in the main display just above the key For example F1 is usually labeled Exit and F4 may be labeled Edit Save or Enter 1 Toenter the main menu press any key 2 Use the and keys to move the cursor to the desired sub menu The position of the cursor is shown in reverse video NOTE When the last item of a menu has been reached the cursor will be on the third line of the display If the cursor is on the second line of the display more items remain Continue pressing the key 3 Press Enter F4 to access a sub menu or an item in a sub menu 4 To change a number or a setting press Edit F4 The display will change to show the cursor on the first digit or on a or sign Use the ab and keys to increase or decrease a digit or to toggle and signs Use the and keys to move the cursor left and right 5 Ifan entire number or a word is highlighted use the and keys to scroll through the list of choices 6 To store a number or setting in memory press Save F4 7 Toleave without storing changes press Esc F3 8 To leave and return to the previous screen press Exit F1 9 To end a calibration step and leave the previous calibration in place press Abort F1 10 Occasionally information screens will appear To leave the information screen and move
67. ndard temperature sensor submerged to the correct level 10 4 TROUBLESHOOTING WHEN NO FAULT MESSAGE IS SHOWING OXYGEN Problem See Section Zero current was accepted but current is greater than about 50 nA Error or warning message while zeroing the sensor zero current is too high Zero reading is unstable Sensor can be calibrated but current is outside the range 1800 3100 nA ppm Possible error warning during air calibration Possible error warning during in process calibration Barometric pressure reading is too high or too low Process readings are erratic Readings drift Sensor does not respond to changes in oxygen level Readings are too low 10 4 1 Zero current is too high Is the sensor properly wired to the analyzer See Section 3 3 B Is the membrane completely covered with zero solution and are air bubbles not trapped against the mem brane Swirl and tap the sensor to release air bubbles C 15 the zero solution fresh and properly made Zero the sensor in a solution of 5 sodium sulfite in water Prepare the solution immediately before use It has a shelf life of only a few days D If the sensor is being zeroed with nitrogen gas verify that the nitrogen is oxygen free and the flow is adequate to prevent back diffusion of air into the chamber E The major contributor to the zero current is dissolved oxygen in the electrolyte solution inside the sensor A long zeroing period usually means that an air bubble is trap
68. nfigure Display Units ppm ppb sat C or F Output 1 mA or FS Output 2 mA or FS Language Line 3 display Display contrast Timeout on or off Timeout limit Polling address Outputs Output 1 and 2 Measurement main snr temp control Output 1 and 2 Range 0 20 or 4 20 mA setup Dampen Hold keep last value Hold go to specified value Fault Hold feature setup Alarm 1 2 amp 3 Measurement main snr pH temp control Alarm 1 2 amp 3 Alarm High low or off setup Setpoint Hysteresis Delay Relay default Alarm 4 setup SE Feed limit Alarm 1 2 or 3 or disable Feed limit timer Timeout Int Iti Timer Alarm 1 2 or 3 or disable nterval timer interval Repeats On time Off time Recovery time Continued on following page 19 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION FIGURE 5 1 Menu Tree for the 54eA Analyzer continued Simulated tests see page 17 Display see page 17 Outputs see page 17 Alarms see page 17 Temperature comp auto or manual T t uolo Units C or F Moise Noise rejection 50 or 60 H Rejection oise rejection 50 or z Barometric Measurement Auto or manual Pressure Units mm Hg kPa atm barg in Hg Stabilize Stabilize time Salinity Lock all Lock configure 20 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION Table 5 1 lists the default settings and the range of choices available for each setting To reduce the cha
69. ng RTD Inputs The figure shows wiring connections for sensors con taining a Pt 100 RTD Pt 100 MODEL 00 03 04 SECTION 11 0 RETURN MATERIAL SECTION 11 0 RETURN OF MATERIAL 11 1 GENERAL To expedite the repair and return of instruments proper communication between the customer and the factory is important Before returning a product for repair call 1 949 757 8500 for a Return Materials Authorization RMA number 11 2 WARRANTY REPAIR The following is the procedure for returning instruments still under warranty 1 Call Rosemount Analytical for authorization 2 verify warranty supply the factory sales order number or the original purchase order number In the case of individual parts or sub assemblies the serial number on the unit must be supplied 3 Carefully package the materials and enclose your Letter of Transmittal see Warranty If possible pack the materials in the same manner as they were received 4 Send the package prepaid to Emerson Process Management IMPORTANT Liquid Division Please see second section of Return of 2400 Barranca Parkway Materials Request form Compliance with Irvine CA 92606 the OSHA requirements is mandatory for the safety of all personnel MSDS forms and a certification that the instruments have been disinfected or detoxified are required Attn Factory Repair RMA No Mark the package Returned for Repair Model No __ 11 3 NON WARRANTY REPAIR
70. nslutning f r att bevara klassificering av apparatsk p HOGSPANNING KAN F REKOMMA Avl gsnande av s kring eller skyddsk pa kan f rorsaka allvarlig skada eller d dsfall IAKTTAG F RSIKTIGHET Para manter sempre uma boa prote o contra inc ndio substituir somente porfusiveis com a tens o e corrente especificadas Os fusiveis encontram se sob esta tampa For kontinuerligt skydd mot brandfara ersatt endast med specificerad s kringsstorlek och spanning MODEL 00 03 04 TABLE OF CONTENTS MODEL DO 03 04 MEASURING SYSTEM TABLE OF CONTENTS Section Title Page 1 0 SPECIFICATIONS rerit rre ETOS 1 1 1 Features and eelere EE 1 1 2 REI e EE 2 1 3 Ordering Iriformiatiori ico eet en e fet ME eU ENEE 6 2 0 INSTALLATION e 7 2 1 Unpacking and Inspection 7 2 2 NEI e 7 3 0 WIRING 2 5E ee dee 12 3 1 erre E 12 3 2 Power Alarm and Output Wiring 12 3 3 Sensor len DEE 16 4 0 DISPLAY AND OPERATION esee nennen nennen nennen nnn nnne n nnns 17 4 1 BIET 17 4 2 Key Functions and Control 17 4 3 KEE 17 5 0 SOFTWARE CONFIGURATION nen nnne nni rien nien 18 5 1 Changing Alarm Setpoint eene 24 5 2 Ranging the eee de o ride d ch ded de ee d d ids 25 5 3 Testing Outputs and 26 5 4 Choosing Display
71. ntennelse skal opprettholdes m sikringer bare Kabelverschraubungen Um die Gefahr von Kurzschluff und Funkenbildung zu verhindern erstattes med tilsvarende som har spesifisert spenning og str mstyrke und Blindkappen d rfen die Sicherungen nur durch solche gleicher Spannung und Sikringer er plassert under dette dekslet Stromwerte ausgetauscht werden Die Sicherungen befinden sich unter dieser Abdeckung auszuruesten AA NIEBEZPIECZENSTWO URZADZENIE MOZE BYC POD NAPIECIEM Gdy bezpieczniki lub ta pokrywa sa usuniete istnieje mozliwosc uszkodzenia ciala lub smierci POSSIBILE PRESENZA DI ALTA TENSIONE La rimozione del fusibile o del coperchio pu causare Uziemij przewod do metaiowego plaskownika lub obudowy Aby zachowac stopien szczelnosci obudowy stosuj niepaine wodoszczelne diawiki gravi lesioni o morte A ATTENZIONE Per garantire una continua protezione contro gli incendi sostituire solo con fusibili del voltaggio indicato e dell attuale potenza I fusibili sono alloggiati sotto il coperchio W celu utrzymania zabezpieczenia przed zapaleniem nalezy stosowac bezpieczniki o identycznym z oryginalnym napieciu i amperazu Bezpieczniki sa umieszczone pod ta pokrywa PERIGO 4 POSSIBILIDADE DE TENSAO PERIGOSA remo o do fusivel ou desta tampa pode causar les es graves ou a morte IAKTTAG RSIK Anslutningspunkt r jordad till chassi Anv nd brands ker vattentat kabela
72. nurled cap provided with the sensor with the smooth cap PN 33521 01 The smooth cap is shipped loose a Hold the sensor with the membrane end pointing up b Unscrew the knurled cap Leave the membrane in place c Screw the smooth cap in place Hand tighten d Hold the sensor with the membrane end pointing down Shake the sensor a few times as though shak ing down a clinical thermometer e Slide the protective cap back over the end of the sensor Remove the set screw at the bottom of the sensor washer head assembly See Figure 2 5 Pull the washer head from the shank You are pulling against a dual O ring seal Press the metal tab on the air hose quick connect fitting and remove the fitting and check valve Wrap the bottom facing threads of the sensor with pipe tape Remove the protective cap and slide the O ring PN 9550291 over the end of the sensor until it rests against the lower edge of the bottom facing thread The O ring is in a bag taped to the side of the washer head assembly Screw the sensor into the bottom of the washer assembly Hand tighten only Replace the air hose and check valve assembly 2 2 7 Assembling the washer head and pipe boom 1 Cement the upper portion of the washer assembly head to the PVC pipe boom See Figure 2 5 Use 1 1 2 inch schedule 80 PVC pipe Press do not cement the PVC elbow PN 9320101 to the top of the pipe boom The elbow keeps water from collecting in the pipe boom Pass the sen
73. ort Cont SS 7 Exit Enter 8 20 ppm Stabilizing Wait Abort Cont From the main display press any key to obtain the main menu With the cursor on Calibrate press Enter F4 NOTE If Hold was enabled in Section 5 5 the hold screen will appear To activate hold refer to Section 5 5 step 9 Press Enter F4 The screen shown in step 5 appears Press Enter F4 to select Calibrate in air This screen shows the barometric pressure and temperature that will be used for the calibration If the barometric pressure or temperature is incorrect press Abort F1 Refer to Section 7 5 for the pressure cali bration procedure Refer to Section 6 2 for the temperature calibration procedure NOTE The barometric pressure sensor is inside the controller enclosure When cable glands are in place and the front panel is tightly closed the enclosure is moderately airtight Therefore as the controller heats or cools the pressure of the air trapped inside the enclosure may be different from ambient Opening the front panel will equal ize the pressure Press Cont F3 Wait flashes until the sensor is stabilized Once air calibration is complete the message Air calibration done appears The display will show the equilibrium solubility of atmospheric oxygen in water at the prevailing temperature and pressure procedure continued on next page 45
74. ped in the electrolyte To ensure the 499ADO sen sor contains no air bubbles carefully follow the procedure for filling the sensor See Section 9 2 If the elec trolyte solution has just been replaced allow several hours for the zero current to stabilize On rare occasions the sensor may require as long as overnight to zero F Check the membrane for damage and replace the membrane if necessary 56 MODEL 00 03 04 SECTION 10 0 TROUBLESHOOTING 10 4 2 Zero reading Is unstable A B C Is the sensor properly wired to the analyzer See Section 3 3 Verify that all wiring connections are tight Readings are often erratic when a new or rebuilt sensor is first placed in service Readings usually stabilize after an hour Is the space between the membrane and cathode filled with electrolyte solution and is the flow path between the electrolyte reservoir and the membrane clear Often the flow of electrolyte can be started by simply hold ing the sensor with the membrane end pointing down and sharply shaking the sensor a few times as though shaking down a clinical thermometer If shaking does not work perform the checks below Refer to the sensor instruction manuals for additional information Verify that the holes at the base of the cathode stem are open use a straightened paperclip to clear the holes Also verify that air bubbles are not blocking the holes Fill the reservoir and establish electrolyte flow to the cathode Refer to the
75. r applicable national or local codes Unused cable conduit entries must be securely sealed by non flammable closures to provide enclosure integrity in compliance with personal safety and envi ronmental protection requirements Use NEMA 4X or IP65 conduit plugs supplied with the instrument to maintain the ingress protection rating IP65 For safety and proper performance this instrument must be connected to a properly grounded three wire power source Proper relay use and configuration is the responsibili ty of the user No external connection to the instru ment of more than 60VDC or 43V peak allowed with the exception of power and relay terminals Any viola tion will impair the safety protection provided Do not operate this instrument without front cover secured Refer installation operation and servicing to qualified personnel WARNING This product is not intended for use in the resi dential commercial or light industrial environ ment per certification to EN61326 About This Document This manual contains instructions for installation and operation of the Model DO 03 04 The following list provides notes concerning all revisions of this document This is the initial release of the product manual The manual has been reformatted to reflect the Emerson documentation style and updated to reflect any changes in the product offering Rev Level Date Notes A 1 04 B 5 04 10 04 Updated Specifications Section 1 0
76. re the analyzer to match the sensor being used 2 The display menu also lets the user customize the third line in the display change timeout values choose a lan guage other than English and change the display contrast 3 Press any key to enter the main menu Move the cursor to Program and press Enter F4 Output setpoints Simulated tests TENE Oxygen Sensor RMT Standard Meas units ppm M Exit SES T Displa Outputs Alarms M Exit 4 Move the cursor to Configure and press Enter 4 5 With the cursor on Display press Enter F4 6 The screen at left appears The default settings shown for Measure Oxygen and Sensor RMT Standard are appropriate for the 499ADO sensor There are no changes to make If you wish to change the units use the key to move the cursor to Meas units and press Edit F4 Use the or 4 keys to scroll through the choices Press Save F4 to store the selection 27 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 4 CHOOSING DISPLAY OPTIONS CONTINUED Temp units C Output 1 mA Output 2 mA Exit Edit 5 a Language English Display left Display right Out 2 Display contrast 40 Timeout On Timeout value 10 min Exit Edit 28 Exit Edit
77. rodes membranes liquid junctions electrolyte o rings catalytic beads etc and Services are warranted for a period of 90 days from the date of shipment or provision Products purchased by Seller from a third party for resale to Buyer Resale Products shall carry only the warranty extended by the original manufacturer Buyer agrees that Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products If Buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty period Seller shall at its option promptly correct any errors that are found by Seller in the firmware or Services or repair or replace F O B point of man ufacture that portion of the Goods or firmware found by Seller to be defective or refund the purchase price of the defective por tion of the Goods Services All replacements or repairs necessitated by inadequate maintenance normal wear and usage unsuitable power sources unsuit able environmental conditions accident misuse improper installation modification repair storage or handling or any other cause not the fault of Seller are not covered by this limited warranty and shall be at Buyer s expense Seller shall not be obligat ed to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by an authorized Seller representative All
78. rritation May be harm ful if swallowed Read Hold the sensor over a container with the cathode pointing down and follow manual Remove the fill plug and allow the electrolyte solution to drain out Inspect the cathode If it is tarnished clean it by gently rubbing in the direction of the existing scratches do not use a circular motion with 400 600 grit silicon carbide finishing paper Rinse the cathode thoroughly with water Wrap the plug with several turns of pipe tape and set aside Prepare a new membrane Hold the membrane assembly with the cup formed by the membrane and mem brane holder pointing up Fill the cup with electrolyte solution Leave the membrane assembly filled with elec trolyte solution and set it aside Hold the sensor at about a 45 degree angle with the cathode end pointing up Add electrolyte solution through the fill hole until the liquid overflows Tap the sensor near the threads to release trapped air bubbles Add more electrolyte solution if necessary Place the fill plug in the electrolyte port and begin screwing it in After several threads have engaged rotate the sensor so that the cathode is pointing up and continue tightening the fill plug Do not overtighten Place a new O ring in the groove around the cathode post Cover the holes at the base of the cathode stem with several drops of electrolyte solution Insert a small blunt probe like a toothpick with the end cut off through the pressure
79. sensor instruction manual for the detailed procedure 10 4 3 Sensor can be calibrated but current in air is too high or too low A B C Is the sensor properly wired to the analyzer See Section 3 3 Verify that all connections are tight Is the membrane dry The membrane must be dry during air calibration A droplet of water on the membrane during air calibration will lower the sensor current and cause an inaccurate calibration If the sensor current in air is very low and the sensor is new either the electrolyte flow has stopped or the mem brane is torn or loose For instructions on how to restart electrolyte flow see Section 10 4 2 To replace a torn membrane refer to Section 9 2 Is the temperature low Sensor current is a strong function of temperature The sensor current decreases about 3 for every C drop in temperature Is the membrane fouled or coated Slime oil and solids inhibit diffusion of oxygen through the membrane reducing the sensor current Clean the membrane by rinsing it with a stream of water from a wash bottle or by gently wiping the membrane with a soft tissue Also increase the air blast cleaning frequency and duration If cleaning the membrane and increasing the air blast frequency do not improve the sensor response replace the membrane and electrolyte solution If necessary polish the cathode See Section 9 2 for more information 10 4 4 Possible error warning during in process calibration This error
80. sor cable and air hose through the boom and elbow Connect the end of the air hose to the barbed fitting on the check valve Push the washer head back onto the shank Use a small amount of grease to lubricate the O rings Replace and tighten the set screw 2 2 8 Attaching the pipe boom to the handrail mounting assembly 1 Slide the tongue of the pipe clamp into the clevis Insert the bolt as shown in Figure 2 3 2 Rest the boom on the maintenance bracket until ready to submerge the sensor in the basin MODEL 00 03 04 SECTION 2 0 INSTALLATION FIGURE 2 3 Attaching the air compressor enclosure to the handrail pipe clamp pon PVC pipe elbow pipe boorr U bolts to secure handrail mounting assembly to pipe FIGURE 2 4 Assembling and attaching the handrail mounting assembly The spring pin not shown shipped with the handrail mounting assembly is not used 10 MODEL 00 03 04 air hose quick disconnect and check valve oxygen sensor ete o ring PN 9550291 head to shank SECTION 2 0 INSTALLATION A P ds shank set screw 2 air hose P d 7 sensor cable po 7 pipe boom sensor washer head assembly FIGURE 2 5 Installing the sensor in the washer head assembly 11 MODEL 00 03 04 SECTION 3 0 WIRING SECTION 3 0 WIRING 3 1 GENERAL WARNING Electrical installation must conform to the National Electrical Code all state and local codes and all plant
81. ss Exit F1 to leave and return to the previous screen If a WARNING message appears press Cont F3 to continue the calibration or press Abort F1 to leave Continuing the calibration after a warning message appears may cause substantial errors in the subsequent measurement Refer to Section 15 4 for assis tance 44 MODEL 00 03 04 SECTION 7 0 CALIBRATION DISSOLVED OXYGEN 7 3 CALIBRATING THE SENSOR IN AIR 1 Remove the sensor from the process liquid Use a soft tissue and a stream of water from a wash bottle to clean the membrane Blot dry The membrane must be dry during air calibration 2 Pour some water in a beaker and suspend the sensor with the membrane about 0 5 inch 1 cm above the water surface To avoid drift caused by temperature changes keep the sensor out of the direct sun 3 Monitor the dissolved oxygen reading and the temperature Once readings have stopped drifting begin the calibration It may take 5 10 minutes for the sensor reading in air to stabilize Stabilization time may be even longer if the process temperature is appreciably different from the air temperature For an accurate calibration temperature measured by the sensor must be stable war S Calibrate main sensor Zero main sensor Adjust temperature hs g Calibrate in air Calibrate in process Barometric pressure Exit BEE cb D 760 mmHg Temperature 25 0 C Press F3 to air cal Ab
82. t includes 3 membrane assemblies and 3 O rings 9210264 1 Dissolved Oxygen Sensor Fill Solution 4 oz 120 mL 9 3 AIR COMPRESSOR PN 9380088 115Vac or PN 9380089 220 Vac The air compressor has no user serviceable parts It does not require lubrication Fuse sizes are shown in the table The fuse is located below the T shaped plastic cover next to the air compressor A DANGER 100 115 Vac AGC 4 4A 250V Hazardous Voltage 230 Vac AGC 2 2A 250V Can cause severe injury or death Disconnect power before servicing 52 MODEL 00 03 04 SECTION 9 0 MAINTENANCE 9 4 AIR BLAST SENSOR WASHER The air blast sensor washer needs little routine maintenance Replace the two large O rings on the base of the washer head and the sensor sealing O ring if they become cut or dirty or if there is evidence of water leaking into the washer head The three O rings are available as a kit PN 24053 00 See Figure 9 2 for replacement parts FIGURE 9 2 Replacement Parts Screw size is for information only Screw cannot be purchased from Rosemount 53 MODEL 00 03 04 SECTION 10 0 TROUBLESHOOTING SECTION 10 0 TROUBLESHOOTING 10 1 OVERVIEW The 54eA analyzer continuously monitors itself and the sensor for faults When the analyzer detects a fault in the oxygen sensor or in the instrument itself it displays a fault message If alarm 4 was enabled the red FAIL LED will also light and relay 4 will activate The outputs will go to 22 00 m
83. t for sensor washer head three O rings and lube The customer must supply a schedule 80 1 1 2 inch PVC pipe boom to immerse the sensor and cleaning head in the aeration basin 2 2 INSTALLATION 2 2 1 General information 1 Although the equipment is suitable for outdoor use do not install it in direct sunlight or in areas of extreme temperatures 2 Install the equipment in an area where vibrations and electromagnetic and radio frequency interference are minimized or absent 3 To keep the analyzer watertight install plugs provided in the unused cable openings Keep the analyzer and sensor wiring at least one foot from high voltage conductors Be sure there is easy access to the analyzer 5 Provide room to allow the sensor and attached piping to be removed from the aeration basin for service A maintenance bracket part of PN 24048 00 can be used to rest the PVC pipe boom on the handrail Figure 2 1 shows the suggested arrangement of the analyzer air compressor and maintenance bracket on the handrail MODEL 00 03 04 SECTION 2 0 INSTALLATION maximum length 12 ft 3 6 m sensor cable maintenance bracket air hose 11 pipe boom supplied by customer power cable FIGURE 2 1 Suggested arrangement of handrail mounting assembly maintenance clamp air compressor enclosure and 54eA analyzer 2 2 2 Installing the analyzer When used in Model DO 03 04 the 54eA analyzer is intend ed to be
84. te the units nA is nanoamps pA is microamps To return to the main display press exit F1 twice Typical zero current for a 499ADO sensor is less than 50 nA A new sensor or a sensor in which the electrolyte solution has been replaced may require several hours occa sionally as long as overnight to reach a minimum current DO NOT START THE ZERO ROUTINE UNTIL THE SENSOR HAS BEEN IN ZERO SOLUTION FOR AT LEAST TWO HOURS d B Calibrate main sensor Adjust temperature Exit Enter J e E 0 0 ppm Sensor must be in zero solution Abort Cont 2 From the main display press any key to obtain main menu With the cursor on Calibrate press Enter F4 NOTE If Hold was enabled in Section 5 5 the hold screen will appear To activate hold refer to Section 5 5 step 9 Press the key once to move the cursor to Zero main sensor Press Enter F4 The screen at left appears Press Cont Wait flashes until the sensor is stabilized Once the zero step is complete the message Sensor zero done appears Press Exit F1 three times to return to the main display NOTE If Hold was activated during calibration Hold Mode Activated will continue to flash in the main display Return the sensor to normal and deactivate Hold Refer to Section 5 5 step 9 NOTE During calibration ERROR and WARNING messages may appear If an ERROR message appears pre
85. the barometric pressure Using the fact that dry air always contains 20 95 oxygen the analyzer calculates the partial pressure of oxygen Once the analyzer knows the partial pressure of oxygen it uses the Bunsen coefficient to calculate the equilibrium solubil ity of atmospheric oxygen in water at the prevailing tem perature At 25 C and 760 mm the equilibrium solu bility is 8 24 ppm Often it is too difficult or messy to remove the sensor from the process liquid for calibration In this case the sensor can be calibrated against a measurement made with a portable laboratory instrument The laboratory instrument typically uses a membrane covered amperometric sensor that has been calibrated against water saturated air t 2 5 o CH o a o o slope sensor current ppm oxygen sat n dissolved oxygen ppm FIGURE 7 1 Sensor Current as a Function of Dissolved Oxygen Concentration MODEL 00 03 04 7 2 ZEROING THE SENSOR SECTION 7 0 CALIBRATION DISSOLVED OXYGEN 1 Place the sensor in a fresh solution of 5 sodium sulfite NajSO3 in water Be sure air bubbles are not trapped against the membrane The current will drop rapidly at first and then gradually reach a stable zero value To monitor the sensor current go to the main display Press any key to obtain the main menu Press the key once to highlight Diagnostic variables Press Enter F4 The sensor current is the second item in the display No
86. to the next screen press Cont F3 4 3 ALARM STATUS Green LEDs labeled 1 2 and 3 indicate when alarm relays 1 2 and 3 are energized The fourth relay indi cates a fault condition When a fault occurs the red LED labeled FAIL lights up a descriptive error mes sage appears and the outputs and alarm relays act as described in Section 5 5 and Section 5 6 under fault value The red LED also indicates when the interval timer rou tine is activated and when the time limit has been reached on a feed limit timer For more information on these subjects see Section 5 6 17 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION SECTION 5 0 SOFTWARE CONFIGURATION Figure 5 1 is an outline of the menu structure FIGURE 5 1 Menu Tree for the 54eA Analyzer Calibrate Calibrate main sensor Zero main sensor Adjust temperature Output trim Main measurement Main sensor current Sensitivity uA ppm Zero current Barometric pressure Noise rejection Software version Device ID Diagnostic Variables Program see following page 18 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION Calibrate see previous page FIGURE 5 1 Menu Tree for the 54eA Analyzer continued Diagnostic Variable see previous page Program Alarm Setpoints Alarms 1 2 and 3 setpoints 4 mA or 0 mA Output setpoints 20 mA Present output current Test output 1 or 2 Simulated tests Test alarm 1 2 3 or 4 7 Sensor type and manufac Co
87. uildup of static charge Table 9 1 gives a list of replacement parts TABLE 9 1 Replacement Parts PART NUMBER DESCRIPTION 23540 05 Enclosure Front with Keyboard 23848 00 Power Supply Circuit Board Shield 23849 00 Half Shield Power Supply 23969 02 PCB CPU and power supply calibrated 115 230 Vac 23969 06 PCB CPU and power supply calibrated 24 Vdc 33281 00 Hinge Pin 33286 00 Gasket Front Panel 33293 00 Enclosure Rear 9010377 Back lit Display LCD Dot Matrix 9510048 Enclosure Conduit Plug 1 2 inch 9 2 OXYGEN SENSOR MODEL 499ADO 54 9 2 1 General The oxygen sensor requires little maintenance Generally the sensor needs attention when the response be comes sluggish or noisy or when readings drift following calibration 9 2 2 Cleaning the membrane Although the air blast cleaner does a good job of keeping the membrane clean a thin film of slime can eventual ly accumulate on the membrane Slime can be removed by rinsing the membrane with clean water A soft cloth or tissue can also be used to wipe the membrane 9 2 3 Replacing electrolyte solution and membrane To replace the membrane or fill solution the sensor must first be removed from the air blast washer head assem bly To remove the sensor from the air blast cleaner 1 A pair of O rings and a set screw hold the two parts of the sensor washer head assembly together Remove the set screw and pull on the bottom of the assembly until it is clear The quic
88. vel security code at a lower level securi ty gate For example the analyzer will accept a level 2 password at a level 1 gate NOTES a A code of 000 disables security for that level b The security feature will not activate until after the timeout period has passed with no key presses c A hold condition will indefinitely prolong the timeout period Security will activate immediately if power is removed and then restored e recall a forgotten code press and hold F4 for five seconds when the security screen appears The code for that level will appear 39 MODEL 00 03 04 5 12 ANALYZER MODE PRIORITY The Model 54 analyzer can function in different modes depending on how it is configured what process condi tions exist and actions an operator may have made To SECTION 5 0 SOFTWARE CONFIGURATION Priority is in the following order from lowest to highest normal fault timer hold feed limit test Each output or relay acts as if it is only in the state of highest priority reconcile these possible modes there is a set priority that determines exactly what will happen to the two 2 current outputs and the four 4 alarm relays in the event of mul tiple modes occurring at the same time See Table 5 2 below NOTE Some of these features may not be in use in the analyzer TABLE 5 2 Analyzer Mode Priority Chart Priority Current Current Alarm Alarm Alarm Output 1 Output 2 Relay 1 Relay 2 Relay 3
89. ygen sensor Smooth membrane retainer for 499ADO sensor Handrail clamp assembly for washer head clamp sensor maintenance kit and elbow Elbow 90 female socket PVC schedule 40 Air blast washer head Air hose 1 4 inch ID x 1 2 inch OD 25 ft 7 6 m Air compressor 115 Vac 60 Hz or 100 Vac 50 60 Hz Air compressor 220 Vac 50 Hz Mounting hardware for air compressor enclosure O ring kit for sensor washer head three O rings and lube MODEL 00 03 04 SECTION 2 0 INSTALLATION SECTION 2 0 INSTALLATION 2 1 UNPACKING AND INSPECTION Inspect the shipping container If it is damaged contact the shipper immediately for instructions If there is no apparent damage unpack the container Be sure all items shown on the packing list are present If items are missing notify Rosemount Analytical immediately The Model DO 03 04 consists of the following items Model or part number Description 54 01 Model 54eA analyzer 2002577 Mounting bracket for Model 54e pipe wall 23544 00 Cable glands kit for Model 54e qty 5 499ADO 54 Model 499ADO oxygen sensor 24057 00 Smooth membrane retainer for 499ADO sensor Handrail clamp assembly clamp sensor maintenance kit and elbow 24049 00 Air blast washer head 24050 00 Air compressor and enclosure with air hose 115 VAC option 03 only 24050 01 Air compressor and enclosure with air hose 220 VAC option 04 only 24051 00 Mounting hardware for air compressor enclosure 24053 00 O ring ki
90. ygen solubili ty factor Manual In manual temperature compensation the analyzer uses the temperature entered by the user to calculate the membrane perme ability correction and oxygen solubility factor It does NOT use the actual process temperature Do NOT use manual temperature com pensation unless the difference between the calibration and meas urement temperatures is less than 2 C Manual temperature compensation is useful if the sensor RTD has failed and a replacement sensor is not available If Manual temperature compensation is selected be sure to enter the desired temperature 35 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 8 NOISE REDUCTION 1 For maximum noise reduction the frequency of the ac power must be entered into the analyzer 2 Press any key to enter the main menu Move the cursor to Program and press Enter F4 3 Move the cursor to Configure and press Enter F4 e gt 4 Move the cursor to Noise rejection and press Enter F4 Temperature Noise rejection Main sensor cal S Exit Enter b 5 To change the frequency setting press Edit F4 Use the key to Ce 7 Noise re ection 60 Hz toggle between 50 and 60 Hz Press Save F4 to store the change Exit Edit A 36 MODEL 00 03 04 SECTION 5 0 SOFTWARE CONFIGURATION 5 9 BAROMETRIC PRESSURE 1 Barometric pressure is used during air calibration

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