Emerson Rosemount FCL Series User manual

Quick Start Guide
00825-0100-3412, Rev AA
June 2019
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. The
following instructions must be adhered to and integrated into your safety program when installing,
using, and maintaining Emerson 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 1-800-999-9307 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 Reference Manual
and per applicable local and national codes. Connect all products to the proper electrical and
pressure sources.
•To ensure proper performance, use qualified personnel to install, operate, update, program, and
maintain the product.
•When replacement parts are required, ensure that qualified people use replacement parts
specified by Rosemount. Unauthorized 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
Installations near flammable liquids or in hazardous area locations must be carefully evaluated by
qualified on site safety personnel. 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 are 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 to protecting your
system. Restrict physical access by unauthorized personnel to protect end users’ assets. This is true
for all systems used within the facility.
Contents
Specifications...............................................................................................................................5
June 2019 Quick Start Guide
Quick Start Guide 3

Install........................................................................................................................................... 7
Wire........................................................................................................................................... 12
EU Declaration of Conformity.....................................................................................................24
China RoHS Table....................................................................................................................... 26
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1 Specifications
Rosemount 1056 Transmitter
For Rosemount 1056 Transmitter specifications, see the Rosemount 1056
Transmitter Reference Manual on Emerson.com/Rosemount: Manual:
Rosemount 1056 Dual-Input Transmitter.
Table 1-1: General Specifications
Characteristic Specification
Sample requirements •Pressure: 3 to 65 psig (122 to 549
kPa abs). A check valve in the inlet
prevents the sensor flow cells from
going dry if sample flow is lost. The
check valve opens at 3 psig (122 kPa
abs). If the check valve is removed,
minimum pressure is 1 psig (108 kPa
abs).
•Temperature: 32 to 122 °F (0 to 50
°C)
•Minimum flow: 3 gal/hr (11 L/hr)
•Maximum flow: 80 gal/hr (303 L/hr);
high flow causes the overflow tube
to back up.
Sample conductivity >50 µS/cm at 77 °F (25 °C)
Process connection ¼-in. OD tubing compression fitting (can
be removed and replaced with barbed
fitting for soft tubing)
Drain connection ¾-in. barbed fitting. Sample must drain
to open atmosphere.
Wetted parts Overflow sampler and flow cell: acrylic,
polycarbonate, Kynar®, nylon, and
silicone
Chlorine sensor: Noryl®, Viton®, wood,
silicone, polyethersulfone, polyester, and
platinum
pH sensor (Rosemount™ 3900VP):
Stainless steel, glass, Teflon®,
polyphenylene sulfide, EPDM, and
silicone
Response time to step change in chlorine
concentration
< 80 sec to 95% of final reading for inlet
sample flow of 3 gph (11 L/hr)
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Table 1-1: General Specifications (continued)
Characteristic Specification
Weight/shipping weight (rounded up to
nearest 1 lb. or 0.5 kg)
Rosemount FCL-01: 10 lb./13 lb. (4.5
kg/6.0 kg)
Rosemount FCL-02: 11 lb./14 lb. (5.0
kg/6.5 kg)
Table 1-2: Sensor Specifications
Characteristic Specification
Free chlorine range 0 to 10 ppm as Cl2. For higher ranges,
consult the factory.
pH correction range 6.0 to 9.5. For samples having pH
between 9.5 and 10.0, consult the
factory. If pH <6.0, correction is not
necessary. For manual pH correction,
choose option -01. For continuous pH
correction, choose option -02.
Accuracy Accuracy depends on the accuracy of the
chemical test used to calibrate the
sensor.
Interferences Monochloramine, permangante, and
peroxides
Electrolyte volume 25 mL (approx.)
Electrolyte life 3 months (approx.); for best results,
replace electrolyte monthly.
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2 Install
2.1 Unpack and inspect
Procedure
1. Inspect the shipping container(s). If there is damage, contact the
shipper immediately for instructions.
2. If there is no apparent damage, unpack the container(s).
3. Ensure that all items shown on the packing list are present.
If items are missing, notify Emerson immediately.
2.1.1 Rosemount™ FCL-01 (free chlorine without continuous pH
correction)
The Rosemount FCL-01 consists of the following items mounted on a back
plate.
1. Rosemount 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 (Rosemount 499ACL-01-54-VP), three membrane
assemblies, and a bottle of electrolyte solution are in a separate package.
2.1.2 Rosemount™ FCL-02 (free chlorine with continuous pH correction)
The Rosemount FCL-02 consists of the following items mounted on a back
plate:
1. Rosemount 1056-03-24-32-AN transmitter with sensor cables
attached.
2. Constant head overflow sampler with flow cells for pH and chlorine
sensors.
3. Stand to hold pH buffer solution during calibration.
The free chlorine sensor (Rosemount 499ACL-01-54-VP), shipped with three
membrane assemblies and a bottle of electolyte solution, and the
Rosemount 3900VP-02-10 pH sensor are in separate packages.
2.2 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.
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CAUTION
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.
4. Be sure there is easy access to the transmitter and sensor(s).
2.3 Sample requirements
Be sure the sample meets the following requirements:
1. Temperature: 32 to 122 °F (0 to 50 °C )
2. Pressure: 3 to 65 psig (122 to 549 kPa abs)
3. Minimum flow: 3 gal/hr (11 L/hr)
2.4 Mounting, inlet, and drain connections
The Rosemount™ FCL is intended for wall mounting only.
Refer to Figure 2-1 or Figure 2-2 for details. The sensor(s) screw into the flow
cell adapters as shown in the figures. For Rosemount FCL-02 (free chlorine
with continuous pH adjustment), you must also install the pH sensor.
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Figure 2-1: Rosemount FCL-01
A. Chlorine sensor
B. Inlet
C. Drain
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Figure 2-2: Rosemount FCL-02
A. pH sensor
B. Chlorine sensor
C. Inlet
D. Drain
A ¼-in. 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. 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.
Important
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.
2.5 Install the sensor(s)
Emerson provides the Rosemount™ FCL with the sensor cable pre-wired to
the transmitter.
Procedure
1. Connect the chlorine sensor (Rosemount 499ACL-01-54-VP) to the
cable labeled CL.
2. Connect the pH sensor (Rosemount 3900-VP-02-10) to the cable
labeled pH.
The terminal end of the sensor is keyed to ensure proper mating with
the cable receptacle.
3. Once the key has slid into the mating slot, tighten the connection by
turning the knurled ring clockwise.
4. Screw the sensor(s) into the plastic fitting(s), which are held in the
flow cell(s) by the union nut.
Do not remove the protective cap on the sensor(s) until ready to put
the sensor(s) in service.
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3 Wire
3.1 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 (ANSI/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.
3.2 Wire analog outputs
Two analog output currents are located on the main circuit board, which is
attached to the inside of the enclosure door.
Figure 3-1 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 3-1: Analog output connections
The analog outputs are on the main board near the hinged end of the
enclosure door.
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.
3.3 Alarm wiring
The alarm relay terminal strip is located just below the power connector on
the power supply board.
See Figure 3-2.
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Figure 3-2: Alarm relay connections
A. Alarm relay 1
B. Alarm relay 2
C. Alarm relay 3
D. Alarm relay 4
1. To remove the cover, grab it by the upper edges and pull straight
out. The relay terminal strip is at the top of the board.
2. Bring the relay wires through the rear conduit opening on the left
hand side of the enclosure and make connections to the terminals
strip.
3. Replace the cover. The two tabs on the back edge of the cover fit into
slots at the rear of the enclosure, and the three small slots in the front
of the cover snap into the three tabs next to the relay terminal strip.
See Figure 3-2. Once the tabs are lined up, push the cover to snap it
in place.
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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.
3.4 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. Wire the sensor to the signal board.
Refer to the wiring diagrams in Figure 3-3 and Figure 3-4.
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Figure 3-3: Wiring Diagram for Free Chlorine Sensor
A. White
B. Resistance temperature device return
C. White/red
D. Resistance temperature device sense
E. Red
F. Resistance temperature device in
G. Clear
H. Resistance temperature device shield
I. +5 V out
J. -4.5 V out
K. Anode shield
L. Orange
M. Anode
N. Cathode shield
O. Gray
P. Cathode
Connect green wire to metal conduit ground plate in bottom of
enclosure.
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Figure 3-4: Wiring Diagram for 3900VP-10 pH Sensor (Blue Cable)
A. White
B. White/red
C. Red
D. Blue
E. Clear (not used)
F. Clear
G. Orange
H. White/gray
I. Gray
J. Resistance temperature device return
K. Resistance temperature device sense
L. Resistance temperature device in
M. Ground solution
N. pH shield
O. In pH/ORP
P. Reference shield
Q. In 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.
3.5 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. Using Quick Start is easy.
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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.
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.
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The screens in Step 5 and Step 6 only appear if you have a
Rosemount™ FCL-02.
5. If you have a Rosemount FCL-01, go to Step 8. Otherwise, choose pH
for Sensor 2 (S2).
6. Choose Analyzer.
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.
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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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