Emerson Rosemount FCL-01 User manual

Reference Manual
00809-0100-3412, Rev AB
October2023
Rosemount™ FCL
Free Chlorine System with Rosemount 1056 Transmitter

Essential instructions
Read this page before proceeding!
Emerson designs, manufactures, and tests its products to meet many national and international standards. Because
these instruments are sophisticated technical products, you must properly install, use, and maintain them to ensure
they continue to operate within their normal specifications. You must adhere to the following instructions and
integrate them into your safety program when installing, using, and maintaining Emerson's Rosemount products.
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.
•Read all instructions prior to installing, operating, and servicing the product.
•If this reference manual is not the correct one, call 1-800-854-8257 or 949-757-8500 to request the correct
reference manual. Save this reference manual for future reference.
•If you do not understand any of the instructions, contact your Emerson representative for 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 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.
•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 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 people, to prevent electrical shock and personal injury.
WARNING
Hazardous area installation
Qualified on-site safety personnel must carefully evaluate installations near flammable liquids or in hazardous areas.
This device is not Intrinisically Safe or Explosion Proof.
To secure and maintain intrinsically safe installation, use an appropriate transmitter/safety barrier/sensor
combination. The installation system must be in accordance with the governing approval agency (FM, CSA, or
BASEEFA/CENELEC) hazardous area classification requirements. Consult your transmitter Reference Manual for
details.
Proper installation, operation, and servicing of this sensor in a hazardous area installation are entirely the
operator's responsibility.
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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.
Be sure to disconnect all hazardous voltages before opening the enclosure.
Disconnect relay contacts made to separate power sources before servicing.
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).
Safety and performance require that this instrument be connected and properly grounded through a three-wire
power source.
Proper use and configuration is the operator's responsibility.
No external power to the instrument of more than 69 Vdc or 43 V peak is allowed, with the exception of power and
relay terminals. Any violation will impair the safety protection provided.
Do not operate this instrument without the front cover secured. Refer installation, operation, and servicing to
qualified personnel.
WARNING
This product is not intended for use in the light industrial, residential, or commercial environments per the
instrument's certification to EN50081-2.
CAUTION
Sensor/process application compatibility
The wetted sensor materials may not be compatible with process composition and operating conditions.
Application compatibility is entirely the operator's responsibility.
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)...................................................................................................................11
Chapter 2 Wiring....................................................................................................................................... 13
2.1 Wire power.................................................................................................................................13
2.2 Analog output wiring................................................................................................................ 13
2.3 Alarm wiring...............................................................................................................................14
2.4 Wire sensor................................................................................................................................ 15
2.5 Use Quick Start.......................................................................................................................... 17
Chapter 3 Display and operation............................................................................................................ 23
3.1 Display........................................................................................................................................ 23
3.2 Keypad........................................................................................................................................ 24
3.3 Program the transmitter.......................................................................................................... 25
3.4 Security....................................................................................................................................... 27
3.5 Using hold.................................................................................................................................. 28
3.6 Configure the main display......................................................................................................29
Chapter 4 Programming the transmitter.............................................................................................. 33
4.1 Programming overview............................................................................................................33
4.2 Default settings......................................................................................................................... 33
4.3 Configuring, ranging, and simulating outputs......................................................................36
4.4 Configuring alarms and assigning setpoints.........................................................................41
4.5 Configuring measurement.......................................................................................................47
4.6 Configuring temperature related settings.............................................................................50
4.7 Configuring security settings...................................................................................................51
4.8 Setting up diagnostics.............................................................................................................. 53
4.9 Resetting the transmitter......................................................................................................... 54
Chapter 5 Calibration............................................................................................................................... 57
5.1 Calibrate menu.......................................................................................................................... 57
5.2 Calibrate temperature.............................................................................................................. 57
5.3 Free chlorine calibration...........................................................................................................58
5.4 pH calibration.............................................................................................................................64
5.5 Calibrating analog outputs...................................................................................................... 69
Chapter 6 Digital communications......................................................................................................... 71
Chapter 7 Maintenance............................................................................................................................73
7.1 Replace sensor circuit board....................................................................................................73
7.2 Chlorine sensor..........................................................................................................................73
7.3 pH sensor................................................................................................................................... 76
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7.4 Constant head flow controller................................................................................................. 77
Chapter 8 Troubleshooting...................................................................................................................... 81
8.1 Overview of troubleshooting...................................................................................................81
8.2 Use the diagnostic feature.......................................................................................................81
8.3 Troubleshooting when a Fault message is showing.............................................................82
8.4 Troubleshooting when a Warning message is showing...................................................... 86
8.5 Troubleshooting when no error message is showing - chlorine........................................ 88
8.6 Troubleshooting when no error message is showing - pH..................................................92
8.7 Troubleshooting when no error message is showing - general......................................... 96
8.8 Simulate chlorine inputs..........................................................................................................97
8.9 Simulate pH input......................................................................................................................98
8.10 Simulating temperature......................................................................................................... 99
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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. 1056-03-24-38-AN 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. 1056-03-24-32-AN Transmitter with sensor cables attached.
2. Constant head overflow sampler with flow cells for pH and chlorine sensors.
3. Stand to hold pH buffer 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. To keep the transmitter enclosure watertight, install plugs (provided) in the unused
conduit openings.
3. Install the system in an area where vibrations and electromagnetic and radio
frequency interference are minimized or absent.
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4. Be sure there is easy access to the transmitter and sensor(s).
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.
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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 vertically on the
left hand side of the transmitter enclosure.
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.
The power connector is at the top of the board.
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. Run the power wiring through the conduit opening nearest the power terminal.
AC power wiring should be 14 gauge or greater.
3. Provide a switch or breaker to disconnect the transmitter from the main power
supply.
4. Install the switch or breaker near the transmitter and label it as the disconnecting
device for the transmitter.
2.2 Analog output wiring
Two analog output currents 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 connectors can be detached for wiring.
TB-1 is output 1. TB-2 is output 2. Polarity is marked on the circuit board.
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Figure 2-1: Analog output connections
The analog outputs are on the main board near the hinged end of the enclosure door.
For best electromagnetic interference/radio frequency interference (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 Alarm wiring
The alarm relay terminal strip is located just below the power connector on the power
supply board.
See Alarm relay connections.
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Figure 2-2: Alarm relay connections
A. Alarm relay 1
B. Alarm relay 2
C. Alarm relay 3
D. Alarm relay 4
Keep alarm relay wiring separate from signal wiring. Do not run signal and power or relay
wiring in the same conduit or close together in a cable 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.
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5. Wire the sensor to the signal board.
Refer to the wiring diagrams in Figure 2-3 and Figure 2-4.
Figure 2-3: Wiring diagram for free chlorine sensor
Table 2-1: Wiring diagram for free chlorine sensor
Terminal slot Wire color Wire function
1 White Resistance temperature device return
2 White/red Resistance temperature device sense
3 Red Resistance temperature device in
4 Clear Resistance temperature device shield
5 N/A +5 V out
6 N/A -4.5 V out
7 Clear Anode shield
8 Gray Anode
9 Clear Cathode shield
10 Orange Cathode
Connect green wire to metal conduit ground plate in bottom of enclosure.
Figure 2-4: Wiring diagram for 3900VP-10 pH Sensor (blue cable)
Table 2-2: Wiring diagram for 3900VP-10 pH Sensor (blue cable)
Terminal
slot
Wire color Wire function
1 White Resistance temperature device return
2 White/red Resistance temperature device sense
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Table 2-2: Wiring diagram for 3900VP-10 pH Sensor (blue cable) (continued)
Terminal
slot
Wire color Wire function
3 Red Resistance temperature device in
4 Blue Solution ground
5 Clear inner drain
(not used)
+5 V out
6 N/A -5 V out
7 Clear shield pH shield
8 Orange pH In
9 Clear Reference shield
10 Gray Reference
Green (connect to green grounding screw at bottom of enclosure).
6. Once the cable has been connected to the board, slide the board fully into the
enclosure while taking up the excess cable through the cable gland.
7. Tighten the gland nut to secure the cable and ensure a sealed enclosure.
2.5 Use 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.
Using Quick Start is easy.
a. A backlit field shows the position of the cursor.
b. To move the cursor left or right, use the keys to the left or right of the ENTER
key. To scroll up or down or to increase or decrease the value of a digit, use
the keys above and below the ENTER key. Use the left and right keys to move
the decimal point.
c. Press ENTER to store a setting. Press EXIT to leave without storing changes.
Pressing EXIT also returns the display to the initial Quick Start screen.
d. A vertical black bar with a downward pointing arrow on the right side of the
screen means there are more items to display. Continue scrolling down to
display all the items. When you reach the bottom of the list, the arrow points
up.
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2. Choose the desired language. Scroll down to display more choices.
3. Choose Free Chlorine for sensor 1 (S1).
4. Choose the desired units for chlorine.
The screens in Step5 and Step6 only appear if you have a Rosemount FCL-02.
5. If you have a FCL-01, go to Step8. Otherwise, choose pH for Sensor 2 (S2).
6. Choose Analyzer.
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7. Choose Live/Continuous. Go to Step9.
8. The screen below appears only if you have an FCL-01. Enter the pH of the process
liquid.
9. Choose the desired temperature units.
The main display appears. The outputs and alarms (if an alarm board is present) are
assigned to default values.
10. To change outputs, alarms, and other settings, go to the Main Menu and choose
Program. Follow the prompts.
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Wiring Reference Manual
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