Emerson 51-DO-03, 51-DO-04, DO-04, DO-03 User Manual

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Instruction Manual

51-DO-03/04/rev.COctober 2004

Model DO-03/04

Dissolved Oxygen Measurement System with Air Blast Cleaner

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical 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 Rosemount Analytical 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 Instruction Manual is not the correct manual, telephone 1- 800-654-7768and 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 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, 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 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 persons, to prevent electrical shock and personal injury.

WARNING

ELECTRICAL SHOCK HAZARD

Making cable connections to and servicing this instrument 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 other applicable national or local codes.

Unused cable conduit entries must be securely sealed by non-flammableclosures to provide enclosure integrity in compliance with personal safety and environmental 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-wirepower source.

Proper relay use and configuration is the responsibility of the user. No external connection to the instrument of more than 60VDC or 43V peak allowed with the exception of power and relay terminals. Any violation 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 residential, commercial or light industrial environment 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.

Rev. Level Date Notes

A1/04 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.

B5/04 Drawings and part numbers were updated on pages 5, 6, 7, and 51.

C10/04 Updated Specifications, Section 1.0.

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

MODEL DO-03/04

TABLE OF CONTENTS

 

MODEL DO-03/04MEASURING SYSTEM

 

 

TABLE OF CONTENTS

 

Section Title

Page

1.0

SPECIFICATIONS...................................................................................................

1

1.1

Features and Applications .......................................................................................

1

1.2

Specifications...........................................................................................................

2

1.3

Ordering Information................................................................................................

6

2.0

INSTALLATION.......................................................................................................

7

2.1

Unpacking and Inspection .......................................................................................

7

2.2

Installation................................................................................................................

7

3.0

WIRING ...................................................................................................................

12

3.1

General....................................................................................................................

12

3.2

Power, Alarm, and Output Wiring ............................................................................

12

3.3

Sensor Wiring..........................................................................................................

16

4.0

DISPLAY AND OPERATION...................................................................................

17

4.1

Display.....................................................................................................................

17

4.2

Key Functions and Control......................................................................................

17

4.3

Alarm Status ............................................................................................................

17

5.0

SOFTWARE CONFIGURATION .............................................................................

18

5.1

Changing Alarm Setpoints.......................................................................................

24

5.2

Ranging the Outputs................................................................................................

25

5.3

Testing Outputs and Alarms ....................................................................................

26

5.4

Choosing Display Options .......................................................................................

27

5.5

Changing Output Parameters..................................................................................

29

5.6

Changing Alarm Parameters ...................................................................................

31

5.7

Temperature Compensation and Temperature Units...............................................

35

5.8

Noise Reduction ......................................................................................................

36

5.9

Barometric Pressure................................................................................................

37

5.10

Main Sensor Calibration Parameters ......................................................................

38

5.11

Security....................................................................................................................

39

5.12

Analyzer Mode Priority ............................................................................................

40

6.0

CALIBRATION - TEMPERATURE..........................................................................

41

6.1

Introduction..............................................................................................................

41

6.2

Temperature Calibration ..........................................................................................

42

7.0

CALIBRATION - DISSOLVED OXYGEN................................................................

43

7.1

Introduction..............................................................................................................

43

7.2

Zeroing the Sensor..................................................................................................

44

7.3

Calibrating the Sensor in Air....................................................................................

45

7.4

Calibrating the Sensor Against a Standard Instrument ...........................................

47

7.5

Calibrating Barometric Pressure..............................................................................

48

8.0

CALIBRATION - CURRENT OUTPUTS.................................................................

49

8.1

Introduction..............................................................................................................

49

8.2

Trimming the Outputs ..............................................................................................

49

i

MODEL DO-03/04

TABLE OF CONTENTS

 

TABLE OF CONTENTS (CONTINUED)

 

Section

Title

Page

9.0

MAINTENANCE ......................................................................................................

50

9.1

Analyzer (Model 54eA-01).......................................................................................

50

9.2

Oxygen Sensor (Model 499ADO-54) ......................................................................

50

9.3

Air Compressor........................................................................................................

52

9.4

Air Blast Sensor Washer .........................................................................................

53

10.0

TROUBLESHOOTING ............................................................................................

54

10.1

Overview..................................................................................................................

54

10.2

Troubleshooting When a Fault Message is Showing..............................................

54

10.3

Troubleshooting When No Fault Message is Showing - Temperature....................

56

10.4

Troubleshooting When No Fault Message is Showing - Oxygen............................

56

10.5

Troubleshooting Not Related to Measurement Problems .......................................

59

10.6

Simulating Inputs - Dissolved Oxygen.....................................................................

59

10.7

Simulating Temperature...........................................................................................

60

11.0

RETURN OF MATERIALS......................................................................................

61

LIST OF TABLES

Table No. Title .........................................................................................................................

Page

5-1

Program Settings List ..............................................................................................

21

5-2

Controller Mode Priority Chart.................................................................................

40

9-1

Replacment Parts ....................................................................................................

50

ii

MODEL DO-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 Analyzer ......................................................

4

1-2

Analyzer Dimensions...............................................................................................

4

1-3

Enclosure Dimensions.............................................................................................

5

1-4

Standard Sensor with Integral Cable.......................................................................

5

1-5

Air Blast Washer Head ............................................................................................

5

2-1

Suggested Arrangement of Handrail Mounting Assembly, Maintenance Clamp,....

 

 

Air Compressor Enclosure, and 54eA Analyzer ......................................................

8

2-2

Pipe Mounting..........................................................................................................

8

2-3

Attaching the Air Compressor Enclosure to the Handrail........................................

10

2-4

Assembling and Attaching the Handrail Mounting Assembly ..................................

10

2-5

Installing the Sensor in the Washer Head Assembly ..............................................

11

3-1

Power Input, Relay, and Output Wiring for 54eA Analyzer......................................

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 Label.............................................................................................................

16

3-5

Oxygen Sensor with Standard Cable ......................................................................

16

3-6

Oxygen Sensor with Optimum EMI/RFI Cable or Variopol Cable...........................

16

4-1

Main Display Screen................................................................................................

17

5-1

Menu Tree for the 54eA Analyzer............................................................................

18

5-2

Low Alarm................................................................................................................

32

5-3

High Alarm...............................................................................................................

32

5-4

Interval Timer ..........................................................................................................

34

7-1

Sensor Current as a Function of Dissolved Oxygen Concentration .......................

43

9-1

Sensor Parts............................................................................................................

52

9-2

Replacement Parts ..................................................................................................

53

10-1

Simulate Dissolved Oxygen.....................................................................................

59

10-2

Three-WireRTD Configuration................................................................................

60

10-3

Simulating RTD Inputs.............................................................................................

60

iii

MODEL DO-03/04

SECTION 1.0

 

SPECIFICATIONS

SECTION 1.0

SPECIFICATIONS

COMPLETE SYSTEM INCLUDES sensor, analyzer, sensor washer head, mounting hardware, and air compressor.

• AIR BLAST CLEANER system can keep DO sensors funtioning up to 3 months or longer.

SENSOR MAINTENANCE is quick and easy.

FEATURE-PACKEDANALYZER:on-boardpressure sensor for completely automatic air calibration, large backlit display, dual outputs, three fully programmable alarm relays.

FEATURES AND BENEFITS

The Model DO-03/04is 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-03/04uses amembrane-coveredamperometric 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 diffusion 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 pre-tensionedmembrane in place. Replacing the electrolyte solution takes only minutes.

The Model DO-03/04includes the rugged,easy-to-useModel 54eA analyzer. The analyzer features two fully programmable4-20mA 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 laboratory instrument. Air calibration is completely automatic. All the user does is expose the sensor towater-saturatedair 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-freeoxygen 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 clearbio-filmfrom 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-secondair 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.

1

MODEL DO-03/04

SECTION 1.0

 

SPECIFICATIONS

SPECIFICATIONS - 499ADO-54SENSOR

Range: 0 to 20 ppm (mg/L)

Wetted parts: Noryl1 Viton2 EPDM, Teflon3, 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-01ANALYZER

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 temperature and current output. Third line is userselectable. Character heights: 1st line - 16 mm (0.6 in.), 2nd and 3rd lines - 7 mm (0.3 in.).

Power:

115 VAC ± 10%, 50/60 Hz ± 6%, 8 W 230 VAC ± 10%, 50/60 Hz ± 6%, 8 W

RFI/EMI: EN-61326

LVD: EN-61010-1

Outputs: Two4-20mA or0-20mA isolated outputs. Continuously adjustable. Outputs can be assigned to oxygen or temperature. Output dampening isuser-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 to operate the air blast cleaner.

Relay 4 - Sensor/analyzer fault alarm

Each relay has a dedicated LED on the front panel.

Relay Contacts: Relays1-3:Epoxy sealed form A contacts, SPST, normally open

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 122°F). Analyzer can be operated between-20and 60°C(-4to 140°F) with some degradation in display quality.

Relative Humidity: 95% (maximum)non-condensing

Temperature correction for membrane permeability: automatic between 0 and 50°C.

Calibration: automatic air calibration or calibration against a standard instrument

Pressure sensor range: 113 to 862 mm Hg (150 to 1150 mbar)

1Noryl is a registered trademark of General Electric

2Viton is a registered trademark of E.I. duPont de Nemours & Co.

3Teflon is a registered trademark of E.I. duPont de Nemours & Co.

2

MODEL DO-03/04

SECTION 1.0

 

SPECIFICATIONS

SPECIFICATIONS - COMPRESSOR FOR AIR BLAST CLEANER SYSTEM

Enclosure: Fiberglass reinforced polyester with polyester cover, NEMA 4x (IP65). 11.9 x 11.9 x 6.9 in (302 x 302 x 175 mm).

Compressor: Oil-less,non-lubricatingpiston 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: 5 to 122°F(-15to 50°C) assuming intermittent operation

Power:

Code -03:115 VAC, 60 Hz or 100 VAC, 50/60 Hz, single phase,1.3 to 1.4 A, starting current 3.88 A, insulation 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: 1-1/2inch 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: 1-1/2inch 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.

SPECIFICATIONS - HANDRAIL MOUNTING ASSEMBLY

Materials of Construction:

Weather cap: Schedule 40 PVC

Pipe clamp and bracket: Aluminum

Clevis: zinc-platedsteel

U-bolts,nuts, and bolts:zinc-platedsteel

Washers: stainless steel

SHIPPING INFORMATION

The Model DO-03/04is 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 ¼ inch barbed fitting for connection at washer head

3

MODEL DO-03/04

SECTION 1.0

 

SPECIFICATIONS

FIGURE 1-1.Suggested arrangement of handrail mounting assembly, maintenance clamp, air compressor enclosure, and 54eA analyzer

WHEN INCH AND METRIC DIMS

ARE GIVEN

MILLIMETER

INCH

FIGURE 1-2.Analyzer dimensions

4