Emerson ROSEMOUNT HMC-C01 User manual

Reference Manual
00809-200-4245, Rev AA
April 2022
HMC -C01 Compression Sample Head

2 Rosemount HMC-C01
Preface
Published by Emerson.
All possible care has been taken in the preparation of this publication, but Emerson and its agents and distributors accept no liability for any
inaccuracies that may be found.
Emerson reserves the right to make changes without notice both to this publication and the products which it describes.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical,
photocopying, recording, or otherwise without the express prior written permission of the copyright holder.
If you require additional technical assistance, request help from
cascade.suppor[email protected]om or Emerson distribution partners. Send
general inquiries to [email protected]m.

3
Important information
Important
Users must read, understand, and comply with the following information before proceeding.
All users, installers, operators, and maintainers must be familiar with operating the leak detection system. To install, start up,
operate, maintain, and service the detector in a safe manner, it is MANDATORY to read all additional instruction manuals shipped
with the unit.
User information
Important
All users must read this page before proceeding!
Emerson designs, manufactures, and tests its products to meet national and international standards. To ensure the product, continues to operate
as designed and within normal specifications, it
MUST be installed, used, and maintained correctly.
The following instructions MUST be adhered to and integrated into your safety program when installing, operating, and maintaining the detector
• Failure to follow the proper instructions may cause:
— Loss of life
— Personal injury
— Damage to property
— Damage to this instrument
— Warranty invalidation
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand the instructions, contact cascade.supp[email protected]m for additional clarification.
• Follow all warnings, cautions, and instructions 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 manual and in accordance with applicable local and
national codes.
• Connect all products to the correct electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson.
• Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID
YOUR WARRANTY
. Look-alike substitutions may result in fire, electrical hazards, or improper operation.
• To prevent electrical shock and personal injury, all equipment doors must be closed and protective covers in place, except when
maintenance is being performed by qualified personnel.
• The information contained in this document is subject to change without notice.

4 Rosemount HMC-C01
General safety notice/residual risk
Installation, operation, and maintenance of the leak detection system must be in accordance with these instructions.
Authorized personnel
Personnel installing, operating, servicing, and maintaining the leak detection system must be instructed, trained and qualified with
the operating company and the manufacturer.
It is the operating company's responsibility to:
• Train staff
• Observe safety regulations
• Follow the safety instructions and procedures in the product manual
Operators must:
• Be trained
• Read and understand all relevant sections of the product manual before commencing work
• Know the safety mechanisms and regulations

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Regulations and Standards
Compliance approvals
Important
The analyzer is designed for use in Non Hazardous areas ONLY .
Waste
disposal
Do not dispose of in household waste.
Only for EC countries:
In accordance with European Directive 2012/19/EU for Waste Electrical and
Electronic Equipment and its implementation into national right, measuring tools that
are no longer usable must be collected separately and disposed of in an
environmentally correct manner.
In accordance with the European Directive 2012/19/EU for Waste Electrical and
Electronic Equipment (WEEE) disposal of the leak detection system when no longer
serviceable must be collected separately and disposed of in an environmentally
correct manner
Regulation/standards Description
IEC 61010-1:2010 +AMD1:2016 CSV
UL
Std.No. 61010-1 (3rd edition)
Safety requirements for electrical equipment for measurement, control, and
laboratory use - Part 1: General requirements.
IEC 61326-1: 2020
Electrical equipment for measurement, control and laboratory use - EMC
requirements - Part 1: General requirements.
2012/19/EU Waste Electrical and Electronic Equipment (WEEE) Directive.
2014/30/EU The Electromagnetic Compatibility Directive.
2014/35/EU The Low Voltage Directive.
FDA 21 CFR 1040.10 Performance standards for light-emitting products – Sec. 10 :Laser products.
NFPA 70 (2021)
National Electrical Code (issued by ANSI: American National Standards Institute
and
NFPA 70: National Fire Protection Association).

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Hazard messages
This document uses the following criteria for hazard messages based on ANSI standards Z535.6-2011 (R2017).
DANGER
Serious injury or death will occur if a hazardous situation is not avoided.
WARNING
Serious injury or death could occur if a hazardous situation is not avoided.
CAUTION
Minor or moderate injury will or could occur if a hazardous situation is not avoided.
NOTICE
Data loss, property damage, hardware damage, or software damage can occur if a situation is not avoided. There is no credible risk of physical
injury.
Physical access
NOTICE
Unauthorized personnel can potentially cause significant damage and/or misconfiguration of end users' equipment. Protect against all intentional or
unintentional unauthorized use.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access to protect users'
assets. This is true for all systems used within the facility.
Safety precautions
The precautions in this manual MUST NOT be changed amended or removed. All
authorized users, installation, operation and maintenance personnel, must observe the
safety precautions and warnings.
The system is NOT designed for use in Hazardous areas.
DANGER
ELECTRIC SHOCK.
Serious injury or death will occur.
The leak detection system operates using mains voltage and must be switched off and the
power cable removed before opening the analyzer.
WARNING
HEAVY ITEM
Serious injury or death could occur.
The leak detection system weighs 1250 kg (2756 lb) and should only be lifted or moved by
a minimum of two people using suitably rated lifting/moving equipment .

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To prevent crushing of hands, feet, or other body parts always wear suitable protective
gloves and footwear when handling.
The selected installation site must be suitable to support the weight of the leak detection
system, cabling and gas sample lines when installed
WARNING
HIGH PRESSURE AIR
Serious injury or death could occur.
The compressed air supply operate at pressures that can cause injury.
WARNING
HAZARD BY WRONG SUPPLY VOLTAGE
Serious injury or death could occur.
The rated voltage for the leak detector is fixed during the manufacture and defined on the
ratings label fitted to the unit.
The voltage at the installation site must meet the rated voltage required.
WARNING
MAINTENANCE
Serious injury or death could occur.
Only authorized maintenance personnel can carry out repair work on the leak detection
system.
On completion verify:
• All tools and equipment are removed.
• No contamination (water/dust) is in the compartments. Leak detector is wiped
clean.
• Vents are clear and free from obstruction.
• Verify that system is in a safe state for operation.
CAUTION
EQUIPMENT DAMAGE
Minor or moderate injury will or could occur
Always follow the procedures detailed in the manual otherwise damage to the leak detector
may result.

8 Rosemount HMC-C01
Only authorized personnel can operate the leak detection system.
Do not operate the leak detection system unless it is physically secured in position and all
electrical and sample gas connections are in place.
CAUTION
AIR SUPPLY
Minor or moderate injury will or could occur
Air provided must be connected from a pressure regulated clean, filtered and moisture free
supply source.

9
Safety and system labels and annotation
Labels are applied to the system in the positions shown below.
Location Label Type Label Fitted

10 Rosemount HMC-C01

Reference Manual
Contents
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Contents
Chapter 1System overview......................................................................................................... 13
Chapter 2 Equipment and Accessories...................................................................................... 15
2.1 Base Conveyor .............................................................................................................15
2.2 Enclosure Internals .......................................................................................................16
2.3 Enclosure Purge ...........................................................................................................16
2.4 Reject Station ................................................................................................................16
2.6 Electrical Panel.............................................................................................................17
2.7 System Controls ...........................................................................................................18
2.8 Compressed Air Preparation.........................................................................................18
Chapter 3 Installation ...................................................................................................................19
3.1 Unloading/Unpacking ...................................................................................................19
3.1.1 Unloading .....................................................................................................................19
3.1.3 Unpacking.....................................................................................................................20
3.2 Installation ....................................................................................................................20
3.2.1 Installation Requirements.............................................................................................20
3.2.2 Electrical Installation.....................................................................................................21
3.3 Flat Top & Friction Top Installation...............................................................................22
3.3.1 Identify chain and sprockets.........................................................................................22
3.3.2 Sprockets and wear strip position ................................................................................22
3.3.3 Align drive and idler sprockets .....................................................................................22
3.3.4 Idler Wheel and Sprocket Locations.............................................................................22
3.3.5 Inspect guide clearance in both straight and corner sections ......................................22
3.3.6 Insert section of chain...................................................................................................23
3.4 Inspect Conveyor..........................................................................................................23
3.4.1 Installation-Chain..........................................................................................................23
3.4.2 Installation- the Catenary Sag ......................................................................................24
3.4.3 Installation/Disassembly-Chain ....................................................................................24
3.4.4 Connect the chain / One Piece Chains with Style D Pins. ...........................................24
3.4.5 Connect the chain/ One Piece Chains with Knurled Style Pins. ..................................24
3.4.6 Connect the chain/ For Two Piece Chains...................................................................25
3.4.7 Connection style may vary by chain series. .................................................................25
Chapter 4 Start Up Procedure 27
4.1 Before You Begin..........................................................................................................27
4.1.1 Prior To Startup ............................................................................................................27
4.1.2 Startup ..........................................................................................................................28
4.1.3 Operation......................................................................................................................29
4.1.4 Shutdown......................................................................................................................29

Contents
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Chapter 5 Maintenance ................................................................................................................ 31
Chapter 6 Scheduled Maintenance ............................................................................................. 33
6.1 GENERAL MAINTENANCE .........................................................................................34
6.1.1 Flat Top and Friction Top Maintenance ........................................................................34
6.1.2 Inspection .....................................................................................................................34
6.1.3 Chain and Sprockets ....................................................................................................35
6.1.4 Flat Top & Friction Top Chain.......................................................................................35
6.1.5 Bearing Lubrication.......................................................................................................36
6.1.6 Acceptable lubricants include: ......................................................................................36
6.1.7 Motor Maintenance.......................................................................................................36
6.1.8 Reducer Maintenance...................................................................................................37
6.1.9 Manufacturers Recommended Lubricants....................................................................37
Chapter 7 Troubleshooting.......................................................................................................... 39

Reference Manual
System Overview
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1 System overview
The HMC-C01 compression sample head is a system which uses 2 conveyors to
compress MAP filled packages in order to squeeze the MAP gas out of any defect in the
package. The MAP gas is then sampled through sampling points placed at the sides, top,
and/or bottom of the package depending on the specific application.
The compression head is designed to be installed alongside the CM-01 base leak
detection system. Please refer to reference manual 00809-0100-4245 for details on the
base unit installation. This document is intended for the personnel who install, operate,
and maintain the detector.
The compression head is designed to be installed as a slot in solution on an existing or
new production line. The main components of the system are summarized below.
A. Base Conveyor
B. System Enclosure Containing Compression Conveyor
C. Enclosure Purge Fan

System Overview
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D. Reject Station
E. Electrical Panel
F. Control Station
G. Compressed Air Preparation

Reference Manual
Equipment and Accessories
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2 Equipment and Accessories
2.1 Base Conveyor
A. Flat top conveyor surface
B. Guide rails – adjustable for different package sizes
C. Package purge point – compressed air knife directed at the surface of the
packages.

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2.2 Enclosure Internals
A. Compression Conveyor
B. Upstream and downstream height adjustment
C. Sampling points
2.3 Enclosure Purge
The enclosure purge fan is located at the top of the system enclosure. When in use it can
direct up to 120 CFM of air into the enclosure. Inside the enclosure 2 deflection plates
direct the airflow to the upstream and downstream side of the system.
The net effect is a slight positive pressure is created inside the enclosure which prevents
ingress of contaminated air. If uncontaminated air needs to be ducted in from another
source then this can be done with the 100mm duct fitting on top of the purge fan.
2.4 Reject Station
The reject station is located after the compression conveyor and has 3 modes of operation:
1. Normal – in this mode any packs identified as a reject will be automatically
rejected at this point with a blast of compressed air.
2. Clean – in this cleaning mode the system rejects all packs detected. (As
nominally no packs should be present during cleaning procedures)

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Equipment and Accessories
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3. Disabled – The reject station can be disabled by not providing reject signal
from the CT4215 base system.
2.6 Electrical Panel
The system electrical panel is shown below
The panel contains the following key components: Safety control circuit, network hub,
isolation switch, PLC, 3 phase to single phase transformer, Power supplies, and conveyor
drives.

Equipment and Accessories
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2.7 System Controls
From left to right:
A. Start
B. Stop
C. Reset
D. Emergency Stop
These controls will be covered in more detail in the statup/shutdown section
2.8 Compressed Air Preparation
The components inside the compressed air preparation box are
A. Regulator
B. Solenoid – This solenoid connects to the reject signal

Reference Manual
Installation
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3 Installation
3.1 Unloading/Unpacking
WARNING
HEAVY ITEM
Serious injury or death could occur.
The leak detection system weighs 1250 kg (2756 lb) and should only be lifted or moved by
a minimum of two people using suitably rated lifting/moving equipment.
To prevent crushing of hands, feet, or other body parts always wear suitable protective
gloves and footwear when handling.
The selected installation site must be suitable to support the weight of the leak detection
system, cabling and gas sample lines when installed.
On receipt of goods, inspect the Tip N Tell and
ShockDot labels fitted to the outside of the
shipping container.
Tip N Tell
White arrow becomes blue when tilted
80° from vertical.
Shock Dot indicator turns red when a potentially
damaging impact has
occurred.
The labels will alert the customer to any
mishandling of the analyzer when in transit.
3.1.1 Unloading
Make sure that unloading personnel are qualified and properly equipped for your particular
unloading situation. Don’t attempt to use a forklift truck if you really require a crane!
Twisted frames are difficult to repair. Use the correct rigging slings and lifting equipment to
avoid any frame twisting. Use lifting sling and chain spreaders to avoid compressing or
bending portions of the conveyor.
Immediately upon arrival of your shipment, inspect the outside carton or skid for damage.
Open the box and inspect for missing items. If your shipment is flawed, stop unloading
and request immediate inspection by the carrier. Take exception on the delivery receipt by
including damage description words; for example, “2 cartons gouged” or “corners
crushed”. Take photos and keep any original containers on hand for carrier inspection, or
it becomes very difficult to get your damages reimbursed.

Installation
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20 Rosemount HMC-C01
Start a document file for each short or damaged shipment, and don’t delay in filing a claim
against the carrier once the amount of damage or loss is known. The time limit is less than
nine months for domestic truck shipments. Claim forms are available from the delivering
carrier.
Plan to have enough room to temporarily store all of the pieces out of the weather. If the
conveyor will not be installed immediately take all necessary precautions to protect your
investment. Lubricate unpainted parts (like shafts), cover the conveyor, and protect it from
being bumped, and store copies of the instructions manual where you can find them later.
Check your shipment to verify that all operating components have arrived safely and that
all parts have been shipped.
3.1.3 Unpacking
Your conveyor will have been shipped on a wooden skid or completely boxed. The drive
components are mounted to the drive section.
Cross-reference your packing slip and/or approval drawings.
In the event, you find a part that you feel you do not need or is not correct for your
conveyor, please contact our Customer Service Department
3.2 Installation
WARNING
HEAVY ITEM
Serious injury or death could occur.
The leak detection system weighs 1250 kg (2756 lb) and should only be lifted or moved by
a minimum of two people using suitably rated lifting/moving equipment.
To prevent crushing of hands, feet, or other body parts always wear suitable protective
gloves and footwear when handling.
The selected installation site must be suitable to support the weight of the leak detection
system, cabling and gas sample lines when installed.
3.2.1 Installation Requirements
Use experienced and trained riggers, millwrights, installers, and licensed electricians.
Supports should be securely added as soon as each section is put into place. Use as many
installers as required for safety. Check machine leveling and adjust it frequently during the
installation. Belt tracking later depends heavily on the levelness of the conveyor.