Emerson Rosemount FCL-01 User manual

Reference Manual
00809-0200-3412, Rev AB
October2023
Rosemount™ FCL
Free Chlorine System with Rosemount 56 Transmitter

Essential instructions
Read this page before proceeding!
Your instrument purchase from Emerson is one of the finest available for your particular application. Emerson
designs, manufactures, and tests its products to meet many national and international standards. Experience
indicates that its performance is directly related to the quality of the installation and knowledge of the user
in operating and maintaining the instrument. To ensure continued operation to the design specifications, read
this Manual thoroughly before proceeding with installation, commissioning, operation, and maintenance of this
instrument. If this equipment is used in a manner not specified by the manufacturer, the protection provided by
it against hazards may be impaired. Failure to follow the proper instructions may cause any one of the following
situations to occur: loss of life, personal injury, property damage, damage to this instrument, and warranty
invalidation.
•Ensure that you have received the correct model and options from your purchase order. Verify that this Manual
covers your model and options. If not, call 1-800-854-8257 or 949-757-8500 to request the correct Manual.
•For clarification of instructions, contact your Rosemount representative.
•Follow all warnings, cautions, and instructions marked on and supplied with the product.
•Use only qualified personnel to install, operate, program, and maintain the product.
•Install equipment as specified in the installation instructions of the appropriate Quick Start Guide and per
applicable local and national codes. Connect all products to the proper electrical and pressure sources.
•Use only factory documented components for repair. Tampering or unauthorized substitution of parts and
procedures can affect the performance and cause unsafe operation of your process.
WARNING
Electrical shock
Making cable connections to and servicing this instrument require access to shock hazard level voltages, which can
cause death or serious injury.
Equipment protected throughout by double insulation.
Disconnect main power and relay contacts wired to separate power sources before servicing.
Do not operate or energize instrument with case open.
Non-metallic cable strain reliefs do not provide grounding between conduit connections. Use grounding type
bushings and jumper wires.
Electrical installation must be in accordance with the National Electrical Code (ANSI/NFPA-70) and/or any other
national or local codes.
Unused cable conduit entries must be securely sealed by non-flammable closures to provide exposure integrity in
compliance with personal safety and environmental protection requirements. Unused conduit openings must be
sealed with NEMA 4X or IP65 conduit plugs to maintain the ingress protection rating (IP65).
Operate only with front and rear panels fastened and in place over terminal area.
Safety and performance require that this instrument be connected and properly grounded through a three-wire
power source.
WARNING
This product is not intended for use in the light industrial, residential, or commercial environments per the
instrument's certification to EN50081-2.
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CAUTION
Radio interference
This product generates, uses, and can radiate radio frequency energy and thus can cause radio communication
interference. Improper installation or operation may increase such interference. As temporarily permitted by
regulation, this unit has not been tested for compliance within the limits of Class A computing devices, pursuant to
Subpart J of Part 15 of FCC rules, which are designed to provide reasonable protection against such interference.
Operation of this equipment in a residential area may cause interference, in which case the operator, at his own
expense, will be required to take whatever measures may be required to correct the interference.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’
equipment. This could be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental in protecting your system. Restrict
physical access by unauthorized personnel to protect end users’ assets. This is true for all systems used within the
facility.
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Contents
Chapter 1 Installation.................................................................................................................................7
1.1 Unpacking and inspection..........................................................................................................7
1.2 General installation information............................................................................................... 7
1.3 Sample requirements................................................................................................................. 8
1.4 Mounting, inlet, and drain connections................................................................................... 8
1.5 Install the sensor(s)...................................................................................................................10
Chapter 2 Wiring....................................................................................................................................... 11
2.1 Wire power.................................................................................................................................11
2.2 Wire analog outputs................................................................................................................. 11
2.3 Wire alarm relays.......................................................................................................................13
2.4 Wire sensor................................................................................................................................ 14
2.5 Quick Start..................................................................................................................................14
Chapter 3 Display and operation............................................................................................................ 17
3.1 Main display............................................................................................................................... 17
3.2 Keypad........................................................................................................................................ 18
3.3 Operation................................................................................................................................... 18
3.4 Hold.............................................................................................................................................21
3.5 Main display............................................................................................................................... 22
3.6 Security....................................................................................................................................... 24
Chapter 4 Programming the transmitter.............................................................................................. 25
4.1 Entering the Program menus.................................................................................................. 25
4.2 Outputs.......................................................................................................................................26
4.3 Relays..........................................................................................................................................26
4.4 Measurement.............................................................................................................................28
4.5 Temperature.............................................................................................................................. 29
4.6 pH diagnostic setup.................................................................................................................. 30
4.7 Security....................................................................................................................................... 31
Chapter 5 Calibration............................................................................................................................... 33
5.1 Calibrate menu.......................................................................................................................... 33
5.2 Entering the Calibration menus.............................................................................................. 33
5.3 Calibrating temperature...........................................................................................................34
5.4 Calibrate the free chlorine sensor...........................................................................................34
5.5 Calibrate the pH sensor............................................................................................................35
5.6 Calibrate the analog outputs................................................................................................... 35
5.7 Reset........................................................................................................................................... 35
Chapter 6 Digital communications......................................................................................................... 37
Chapter 7 Data and event logging and retrieval.................................................................................. 39
7.1 Data and event logging overview........................................................................................... 39
7.2 Configure data and event logging and retrieval................................................................... 40
7.3 Download data and events...................................................................................................... 40
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7.4 View events................................................................................................................................ 41
7.5 Reset date and time.................................................................................................................. 41
Chapter 8 Graphical display.....................................................................................................................43
8.1 Graphical display overview...................................................................................................... 43
8.2 Configure graphical display..................................................................................................... 43
Chapter 9 Maintenance............................................................................................................................45
9.1 Replace sensor circuit board....................................................................................................45
9.2 Chlorine sensor..........................................................................................................................45
9.3 pH sensor................................................................................................................................... 47
9.4 Constant head flow controller................................................................................................. 48
Chapter 10 Troubleshooting...................................................................................................................... 51
10.1 Overview of troubleshooting.................................................................................................51
10.2 Read and troubleshoot Fault and Warning messages....................................................... 51
10.3 Use sensor diagnostics...........................................................................................................52
10.4 Troubleshoot calibration problems...................................................................................... 52
10.5 Troubleshooting chlorine measurement errors................................................................. 53
10.6 Troubleshooting - pH..............................................................................................................55
10.7 Other troubleshooting - general...........................................................................................57
10.8 Simulate chlorine inputs........................................................................................................58
10.9 Simulate pH input................................................................................................................... 59
10.10 Simulating inputs - temperature.........................................................................................60
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1 Installation
1.1 Unpacking and inspection
Procedure
1. Inspect the shipping container(s). If there is damage, then contact the shipper
immediately for instructions.
2. If there is no apparent damage, then unpack the container(s).
3. Ensure that all items shown on the packing list are present.
If items are missing, then notify Emerson immediately.
1.1.1 Rosemount FCL-01 (free chlorine without continuous pH
correction)
The FCL-01 consists of the following items mounted on a back plate.
1. 56-03-24-38-HT Transmitter with sensor cable attached.
2. Constant head overflow sampler with flow cell for chlorine sensor.
The free chlorine sensor (499ACL-01-54-VP), three membrane assemblies, and a bottle of
electrolyte solution are in a separate package.
1.1.2 Rosemount FCL-02 (free chlorine with continuous pH
correction)
The FCL-02 consists of the following items mounted on a back plate:
1. 56-03-24-38-HT Transmitter with sensor cables attached.
2. Constant head overflow sampler with flow cells for pH and chlorine sensors.
3. Stand to hold pH buffer solution during calibration.
The free chlorine sensor (499ACL-01-54-VP), shipped with three membrane assemblies and
a bottle of electrolyte solution, and the 3900VP-02-10 pH Sensor are in separate packages.
1.2 General installation information
1. Although the system is suitable for outdoor use, do not install it in direct sunlight or
in areas of extreme temperature.
WARNING
Hazardous areas
The system is not suitable for use in hazardous areas.
2. Install the system in an area where vibrations and electromagnetic and radio
frequency interference are minimized or absent.
3. Be sure there is easy access to the transmitter and sensor(s).
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1.3 Sample requirements
Be sure the sample meets the following requirements:
1. Temperature: +32 to +122 °F (0 to +50 °C )
2. Pressure: 3 to 65 psig (0.2 to 4.5 barg)
3. Minimum flow: 3 gal/hr (11 L/hr)
1.4 Mounting, inlet, and drain connections
The Rosemount FCL is intended for wall mounting only.
Refer to Figure 1-1 or Figure 1-2 for details. The sensor(s) screw into the flow cell adapters
as shown in the figures. For FCL-02 (free chlorine with continuous pH adjustment), you
must also install the pH sensor.
Figure 1-1: FCL-01
Dimensions are shown with inches above and millimeters below.
A. Chlorine sensor
B. Inlet
C. Drain
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Figure 1-2: FCL-02
Dimensions are shown with inches above and millimeters below.
A. pH sensor
B. Chlorine sensor
C. Inlet
D. Drain
A ¼-in. outer dimension (OD) tubing compression fitting is provided for the sample inlet.
If desired, you can remove the compression fitting and replace it with a barbed fitting.
The fitting screws into a ¼-in. female NPT (FNPT) check valve. The check valve prevents the
sensor flow cell from going dry if sample flow is lost.
The sample drains through a ¾-in. barbed fitting.
1. Attach a piece of soft tubing to the fitting and allow the waste to drain to open
atmosphere.
NOTICE
Do not restrict the drain line.
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2. Adjust the sample flow until the water level is even with the central overflow tube
and excess water is flowing down the tube.
3. Confirm that sample is flowing through the flow cells.
1.5 Install the sensor(s)
Emerson provides the Rosemount FCL with the sensor cable pre-wired to the transmitter.
Procedure
1. Connect the chlorine sensor (499ACL-01-54-VP) to the cable labeled CL.
2. Connect the pH sensor (3900-VP-02-10) to the cable labeled pH.
The terminal end of the sensor is keyed to ensure proper mating with the cable
receptacle.
3. Once the key has slid into the mating slot, tighten the connection by turning the
knurled ring clockwise.
4. Screw the sensor(s) into the plastic fitting(s), which are held in the flow cell(s) by the
union nut.
Do not remove the protective cap on the sensor(s) until ready to put the sensor(s) in
service.
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2 Wiring
2.1 Wire power
Wire AC mains power supply to the power supply board, which is mounted on the left hand
side of the transmitter enclosure beneath the gray plastic cover.
WARNING
Electrical shock
Electrical installation must be in accordance with the National Electrical Code (American
National Standards Institute [ANSI]/National Fire Protection Association [NFPA]-70) and/or
any other applicable national or local codes.
Procedure
1. Unplug the connector from the board and wire the power cable to it.
Lead connections are marked on the connector. (L is live or hot; N is neutral; the
ground connection has the standard symbol.)
2. Provide a switch or breaker to disconnect the transmitter from the main power
supply.
3. Install the switch or breaker near the transmitter and label it as the disconnecting
device for the transmitter.
2.2 Wire analog outputs
Four analog current outputs are located on the main circuit board, which is attached to the
inside of the enclosure door.
Figure 2-1 shows the locations of the terminals, the outputs they are assigned to, and the
polarity.
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Figure 2-1: Analog Output Connections
A. Hinge pin
B. To power supply PCB (ribbon cable)
C. To digital I/O communication board
D. To sensor 1 signal board
E. To sensor 2 signal board
The analog outputs are on the main board near the hinged end of the enclosure door.
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For best EMI/RFI protection, use shielded output signal cable enclosed in earth-grounded
metal conduit.
Keep output signal wiring separate from power wiring. Do not run signal and power or
relay wiring in the same conduit or close together in a cable tray.
2.3 Wire alarm relays
The alarm relay terminal strip is located on the power supply board, which is mounted on
the left hand side of the enclosure beneath the gray plastic cover.
Figure 2-2: Alarm Relay Connections
A. Alarm relay 1
B. Alarm relay 2
C. Alarm relay 3
D. Alarm relay 4
E. Earth ground
F. Neutral
G. Line power
H. To main board (ribbon cable)
Procedure
1. To remove the cover, grab it by the upper edges and pull straight out.
The relay strip is at the top of the terminal board. See Figure 2-2.
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2. Bring the relay wires through the rear conduit opening on the left hand side of the
enclosure and make connections to the terminal strip.
3. Replace the cover.
The two tabs on the back edge of the cover fit into slots at the rear of the enclosure,
and the three small slots on the front of the cover snap into the three tabs next to
the relay terminal strip. See Figure 2-2.
Keep alarm wiring separate from signal wiring. Do not run signal and power or relay
wiring in the same conduit or close together in a tray.
2.4 Wire sensor
The Rosemount FCL is provided with sensor cables pre-wired to the transmitter. If it is
necessary to replace the sensor cable, refer to the instructions below.
Procedure
1. Shut off power to the transmitter.
2. Loosen the four screws holding the front panel in place and let it drop down.
3. Locate the appropriate signal board.
Slot 1 (left) Slot 2 (center) Slot 3 (right)
Communication Input 1 (chlorine) Input 2 (optional)
4. Loosen the gland fitting and carefully push the sensor cable up through the fitting
as you pull the board forward to gain access to the wires and terminal screws.
5. Once the cable has been connected to the board, slide the board fully into the
enclosure while taking up the excess cable through the cable gland.
6. Tighten the gland nut to secure the cable and ensure a sealed enclosure.
2.5 Quick Start
Procedure
1. Once connections are secured and verified, apply power to the transmitter.
When the transmitter is powered up for the first time, Quick Start screens appear.
a. The cursor, shown by dark blue backlighting, is on the language control
box. To change the language, press the ENTER/MENU key. A list of available
languages, shown two at a time, appears. Using the Up and Down keys,
scroll (see ) to display the choices. Press ENTER/MENU to select the desired
language. Press Down to move the cursor to the temperature control box. To
change units, press ENTER/MENU and scroll to either °F or °C. Press ENTER/
MENU to store the selection.
b. To move to the next screen, use the navigation keys to move the cursor to
NEXT and press ENTER/MENU.
2. The next screen lists navigation rules. Press ENTER/MENU for the next screen.
3. Configure sensor 1.
Sensor 1 is the free chlorine sensor. The screen has three control boxes.
a) For measurement, choose Free chlorine.
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Important
Do not choose pH-independent free chlorine.
b) Choose the desired units, mg/L or ppm.
c) If you have a Rosemount™ FCL-02 (with pH sensor), the third control box lets
you choose between live/continuous or manual pH correction.
If you choose live/continous (recommended), the transmitter will use the pH
measured by the pH sensor to correct the chlorine reading for pH changes. If
you choose manual (not recommended), a fourth control box appears to let
you enter the manual pH, and the transmitter will use the entered value to
correct the chlorine reading.
d) If you have a Rosemount FCL-01 (no pH sensor), enter the pH of the process
liquid in the third control box.
e) Move the cursor to NEXT and press ENTER/MENU. If you have a Rosemount
FCL-01, the display changes to show some basic keypad operation guidelines.
Press ENTER/MENU to show the main display. If you have a Rosemount, go to
the next step.
4. Configure sensor 2.
Sensor 2 is the pH sensor. The screen has two control boxes.
a) For measurement, choose pH.
b) For pre-amplifier location, choose analyzer.
c) Move the cursor to NEXT and press ENTER/MENU. The display changes to
show some basic keypad operation guidelines. Press ENTER/MENU to show
the main display.
The outputs, alarms, display configuration, and data logging are all assigned to default
values. The default value for data logging is disabled.
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3 Display and operation
3.1 Main display
The transmitter has a four line display.
See Figure 3-1. The display can be customized to meet your requirements. Fault or
warning messages, if appropriate, appear at the bottom of the screen. See Overview of
troubleshooting.
Figure 3-1: Main display
The following abbreviations are used in the lower two lines of the display. The number
following the display refers to the sensor, alarm relay, or output.
OOutput
T Temperature (live)
Tm Temperature (manual)
M Measurement
AL Alarm relay
I Sensor current (chlorine)
mV mV input (pH)
Slp slope (pH)
R.Z. reference impedance (pH)
Gl.Z. glass impedance (pH)
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3.2 Keypad
Local communication with the transmitter is through the membrane keypad.
See Figure 3-2.
Figure 3-2: Transmitter Keypad
A. Press INFO to get more information about the control setting or calibration step the
cursor is on. To close the INFO box, press any key.
B. Use the alphanumeric keypad to enter numbers or letters.
C. When the main display is showing, press ENTER/MENU to view the main menu. In other
cases, press ENTER/MENU to select an item for editing or to store a change.
D. Four navigation keys move the cursor up, down, left, and right.
E. Press EXIT to return the display to the first screen in a series of related screens. Changes
that have not been stored will not be saved.
3.3 Operation
The operation of the Rosemount 56 Transmitter can best be understood from the following
example.
Procedure
1. With the main display showing (Figure 3-1), press ENTER/MENU.
The main Menu, shown below, appears.
Important
Pressing the ENTER/MENU key will bring up the main Menu only if the main display
is showing.
Note that the current reading and temperature for sensor 1 (S1) and sensor 2 (S2), if
applicable, always appear at the top of the screen.
The cursor (dark blue backlit field) is on Calibrate.
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2. Press Down to move the cursor to Program.
3. Press ENTER/MENU.
The cursor is on Outputs, and the first screen in the Outputs submenu is showing.
4. To select a different program submenu, use Right to move the cursor to the desired
tab and press ENTER/MENU.
5. To enter the Outputs submenu, press Down.
The cursor moves to the first control box, Output. The Rosemount 56 has four
analog outputs, and this control lets you select which output to configure. The
default is output 1.
6. To select a different output, press ENTER/MENU.
A list of the available outputs, shown two at a time, appears.
7. To view the list, press or press and hold Up or Down. To select and store
the highlighted selection, press ENTER/MENU. To move from one control box to
another, press Up or Down.
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Some controls require you to select an item from a list. Others, like Dampening,
require you to enter a number.
8. Move the cursor to Dampening at the bottom of the screen.
The default Dampening value is 0 seconds.
9. To change the value, press ENTER/MENU.
The dark blue back-lighting disappears, indicating that a number can be entered.
10. Use the numeric keypad to enter the desired number. If you make an error, press
Left to erase the digit last entered. To store the number, press ENTER/MENU.
Every control box has an information or help screen associated with it.
11. To view the information screen for the control box the cursor is on, press INFO.
The information screen for Dampening is shown below.
12. To close the information screen, press any key.
A NEXT and BACK button are at the bottom of the screen. NEXT means that
additional control boxes are available on at least one or more screen.
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