Emerson IM-106-5500 User Manual
Instruction Manual
IM-106-5500, Orignal Issue
August 2005
CCO 5500
Carbon Monoxide (CO) Analyzer
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Instruction Manual
IM-106-5500, Original Issue
August 2005
CCO 5500 Carbon Monoxide (CO) Analyzer
CCO 5500
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
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
product.
• If you do not understand any of the instructions, contact your
Rosemount Analytical representative for clarification.
• Follow all warnings, cautions, and instructions
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
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 VOID YOUR WARRANTY
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.
prior to installing, operating, and servicing the
and integrated
marked on and
to install,
.
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The information contained in this document is subject to change without
notice.
Instruction Manual
N
IM-106-5500, Original Issue
CCO 5500
August 2005
PREFACE The purpose of this manual is to provide information concerning the
components, functions, installation and maintenance of the CCO 5500.
Some sections may describe equipment not used in your configuration. The
user should become thoroughly familiar with the operation of this module
before operating it. Read this instruction manual completely.
DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS, and NOTES
found throughout this publication.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of
effectiveness.
SYMBOLS
NOTE
Highlights an essential operating procedure, condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETI
NOTE TO USERS
The number in the lower right corner of each illustration in this publication is a
manual illustration number. It is not a part number, and is not related to the
illustration in any technical manner.
ii
Instruction Manual
IM-106-5500, Original Issue
August 2005
CCO 5500
Table of Contents
Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SECTION 1
Description and
Specifications
SECTION 2
Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Infrared Transmitter Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Infrared Receiver Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Signal Processor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Air Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Isolating Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Principles and Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Calculation of Gas Concentration. . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Error Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Calculation Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Normalization Equations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Electrical Supply Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
AC Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Normalizing Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Plant Status Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Unpacking the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Selecting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Points to Consider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Duct Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Isolating Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Air Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Transmitter and Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Signal Processor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Installation of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
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CCO 5500
Instruction Manual
IM-106-5500, Original Issue
August 2005
SECTION 3
Configuration and
Startup
SECTION 4
Normal Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Power Supply Voltage Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Turning the Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Detector Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Receiver Gain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Signal Processor Gain Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Transmitter Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Source Intensity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Chopper Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Current Output Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Normal Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Key Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Program Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Parameter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Averages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Plant Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Normalization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Display Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Detector Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Chopper Motor Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
YVals and Gas ppm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Security Code Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Set Averages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Configure O/P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Normalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Setting the Normalizing Parameters. . . . . . . . . . . . . . . . . . . . . . . 4-18
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Water Vapor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Reset Averages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Check Cell Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Normal Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
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Instruction Manual
IM-106-5500, Original Issue
August 2005
CCO 5500
Routine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Notes for Using a Rosemount Analytical Check Cell . . . . . . . . . . 4-21
Alarms and Emergency Conditions . . . . . . . . . . . . . . . . . . . . . . . 4-23
Emergency Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Isolation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Interface with Integrated Emissions Monitoring System . . . . . . . . 4-23
SECTION 5
Maintenance
SECTION 6
Troubleshooting
SECTION 7
Returning Material
SECTION 8
Replacement Parts
Routine (Preventive) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cleaning Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Replacement of the Heater Element . . . . . . . . . . . . . . . . . . . . . . . 5-1
Replacement of Chopper Motor Assembly. . . . . . . . . . . . . . . . . . . 5-2
Replacement of Gas Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Span Factor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Fault Finding with the Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Data Valid LED Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Heater Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Chopper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
LED Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Test Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
APPENDIX A
Safety Data
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
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Instruction Manual
IM-106-5500, Original Issue
August 2005
TOC-4
Instruction Manual
IM-106-5500, Original Issue
August 2005
CCO 5500
Section 1 Description and Specifications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Principles and Modes of Operation . . . . . . . . . . . . . . . . . page 1-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-11
OVERVIEW Rapid advances in the design of 'across the duct' infrared gas analyzers have
led to the general acceptance of this technique for the monitoring of gas levels
in flue gases of power generation boilers and large industrial process steam
boilers.
The CCO 5500 is designed to operate on duct widths of less than 26 ft (8 m)
at flue gas temperatures up to 572
makes installation extremely simple, and through the use of microprocessor
technology they have many advanced features:
• Local normalizing inputs for compliance with legislation requirements
• Serial data facility to allow communication between analyzers and a
central data logging station
• User-definable output in either mg/m
• Four rolling averages are held - selectable from 10 seconds to 30 days
• Integral, back lit 32 character LCD provides diagnostic and
measurement information
• Plant status input to prevent emissions dilution during plant off periods
o
F (300oC). Their rugged construction
3
, mg/Nm3 or ppm
SYSTEM DESCRIPTION The CCO 5500 Carbon Monoxide (CO) Analyzer Monitor consists of four
items (Figure 1-1):
• An infrared transmitter unit to project a beam of infrared radiation
across the duct
•A receiver to measure that radiation
•A power supply unit to provide the necessary power rails, and
•A signal processor to compute the gas concentration from the signals
provided by the receiver unit.
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CCO 5500
SerialDataPo
Figure 1-1. Typical System Layout
Instruction Manual
IM-106-5500, Original Issue
August 2005
Each of these units is designed to be rugged and durable. They are all fully
sealed to IP65 standards and are suitable for outside mounting, without the
need for further weatherproof enclosures.
Transmitter
Isolation Valve
(If Used)
Pressure
Regulator
33 ft(10 m) Max.
Power Supply
Signal Processor
Site Mounting
Flange
Receiver
Air Purge
Purge Air
33 ft(10 m) Standard
Mains Supply &
Contact Outputs
Analogue Outputs,
Normalizing Inputs &
rt
82 ft(25 m) Maximum Total Cable Length
Between Receiver & Power Supply
Infrared Transmitter Unit At the heart of this unit is a small heater assembly designed to give a high
intensity uniform source of infrared energy over a long lifetime, in excess of
two years continuous operation, with a power consumption of only 26 watts.
The heater has a stainless steel cylindrical core, plasma coated with
refractory, and around which is a 'Kanthal' heating element. This is then
enclosed within refractory fibers and encapsulated in an aluminium cartridge.
In the infrequent event of failure, the complete heater assembly can be
replaced on site within ten minutes.
1-2
Instruction Manual
IM-106-5500, Original Issue
August 2005
Figure 1-2. Transmitter and Receiver Schematic
Chopper Blade Detector
Chopper Blade & Motor
The radiation emitted by the heater is then 'chopped' by a motor-driven disc,
and focused across the duct by a lens. The chopper disc is driven by a small
DC motor. The phase and frequency of the chopper disc are monitored by a
radiation detector to provide a reference signal that is utilized by the signal
processor unit.
System calibration is achieved by a small calibration cell containing pure
reference gas (CO) that can be swung into the sight path by means of a
'stepper' motor and gearbox assembly to enable continuous calibration
updates to be maintained. The chopper motor and stepper motor represent
the only moving components in the entire system.
A printed circuit board mounted at the front of the unit provides control
circuitry for the heater, the motors, and the reference wave detector.
Figure 1-2 illustrates the transmitter and receiver units.
Calibrating Cell
CCO 5500
Detector D2
Gas Filter
Detector D1
Heated Infrared Source
Control Detector
Stepper Motor & Gearbox
Reference Detector
Beam Splitter
Interference Filter
Infrared Receiver Unit The precision and reliability which CO concentration levels can be measured
governs the performance of the complete instrument. For this reason design
efforts have been concentrated in producing an extremely simple and robust
receiver unit. It contains no moving parts, is fully sealed and designed to give
many years of trouble-free and maintenance-free operation.
The unit comprises a lens to focus radiation received from across the duct,
followed by a precision interference filter to limit the wave band of energy
used. This filter tolerance is strictly controlled since it alone determines the
instrument scale shape and calibration. The radiation then passes to an
optical beam-splitter where approximately half the radiation is reflected at
right angles directly onto a radiation detector. The other half of the radiation is
transmitted, by the beam-splitter, through a gas cell containing pure reference
gas (CO) and onto a second radiation detector.
The detectors used are lithium tantalate pyro-electric detectors, renowned for
their sensitivity, stability and ability to operate at normal ambient
temperatures, without the need for cooling. They respond only to changing
levels of radiation and thus to the chopped radiation from the infrared source
unit and not to background radiation from the flue or flue gas. The detector
signals are amplified and fed to the signal processor unit.
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Instruction Manual
IM-106-5500, Original Issue
CCO 5500
August 2005
Signal Processor Unit The signal processor unit is housed in a fully-sealed cast-aluminum
enclosure. It houses the microprocessor to monitor the data from the receiver
and produces a 4-20 mA output signal for gas levels within the flue.
A non-volatile RAM section - requiring no battery back-up - enables all of its
operation data to be retained during a power down condition. The instrument
can resume operation immediately when power is restored without having to
be recalibrated.
All operation data is entered via a surface-mounted keypad. A 32-character
LCD provides the operator with measurement details and diagnostic
information.
Inputs are available to receive the 4-20 mA outputs of normalizing
measurement transducers - O
data can also be entered via the keypad or via the serial data port.
A serial communication facility within the processor allows the instrument to
communicate with other Rosemount analyzers and a central data logging unit.
, temperature and pressure, if required. This
2
Power Supply Unit The power supply unit is housed in a fully-sealed cast-aluminium enclosure
and contains the power supplies for the instrument. A switched mode power
supply is utilized to provide an extremely stable power source, able to cope
with large fluctuations in the supply voltage. The contact outputs are also
taken from this unit - data valid and high gas alarm.
Air Purge The air purge unit has its own integral adjustable mount and provides the
interface between the site mounting flange and the transmitter and receiver
units. The purge is designed to provide a steady laminar flow of air away from
the instrument lens, preventing optical contamination.
A supply of air to the purge is essential.
Isolating Valves Isolating valves, if required, may be attached between the air purges and the
duct. These will allow protection for personnel servicing instruments on high
pressure ducts.
PRINCIPLES AND MODES OF OPERATION
Calculation of Gas Concentration
Gas levels are determined by measuring the absorption of infrared radiation,
transmitted through the flue gas, in a wave band sensitive to absorption by the
measurement gas. CCO 5500 monitors have two detectors; one measures
the radiation directly to provide a live output, sensitive to the measurement
gas, while a second detector measures the radiation after passing through a
gas cell filled with pure reference gas (CO), to provide a reference
measurement, completely unaffected by the measurement gas.
1-4
Instruction Manual
IM-106-5500, Original Issue
August 2005
The basic expression from which the gas concentration in the gas is
determined is:
Y = G - K. D2/D1
Where D1 = the reference output from the detector
D2 = the live output from the detector
G = a scaling factor (1600)
K = a constant, known as the zero correction
factor, set so that when there is zero
measurement gas in the duct, Y = 0
thus, K = G. D1(0)
D2 (0)
This parameter Y is then smoothed, linearized and compensated for effects of
path length and flue gas temperature, to produce a measurement of gas
concentration in the flue gas.
CCO 5500
Error Compensation The accurate determination of gas concentration depends on the
measurement of the radiation levels received by the detectors. Any error in
that measurement caused by detector drift will produce errors in the
determination of the gas level. In order to maintain accuracy, it is necessary to
be able to compensate for such drifts. In the CCO 5500 analyzer a technique
of continuous calibration adjustment is used.
The operating cycle of the instrument is in two parts. First, measurements are
obtained from the two detector outputs D1 and D2. The calibration cell,
containing pure CO, is then positioned in the sight path and the two detector
outputs are measured again to give readings E1 and E2.
From the basic scale shape equation:
Y = G - K. D2/D1
and from the calibration equation
Yo = G - K. E2/E1
or K = (G - Yo). E1/E2
thus substituting in the scale shape equation
Y = G - (G - Yo). E1/E2. D2/D1
The two ratios E1/D1 and E2/D2, being derived each from one detector, are
independent of any detector drift, thus making the instrument output
independent of any drift or change in detector gain characteristic.
This operating routine, giving measurements first of D1 and D2 and then, with
the calibration cell in position, of E1 and E2, is repeated continuously and
provides an effective continuous calibration update to enable accuracy to be
maintained at all times.
1-5
Instruction Manual
IM-106-5500, Original Issue
CCO 5500
August 2005
Calculation Sequence The calculations for one complete operating cycle of the instrument are given
below:
•measure D1 & D2
• measure E1 & E2
• compute Y
• smooth Y
• linearize and correct for path length
• normalize measurement
• smooth to produce final gas outputs
Normalization Equations Normalization of data collected by the analyses is essential to compare
emission levels of pollutants into the atmosphere. Software in Rosemount
Analyzers perform all calculations and provides results in various units, vpm,
3
mg/m
and mg/Nm3; derivation of these results is described in this section.
CCO 5500 CO analyzers are cross-duct type and thus measure the quantity
(or number of molecules) of gas within their sight path. This measurement is
converted into a concentration which is fully compensated for the expansion
effects of temperature, while assuming constant atmospheric pressure. This
basic measurement is referred to as 'ppm' (parts per million). However, to
obtain a true concentration 'vpm' (ppm by volume) the 'ppm' value must be
normalized for pressure using the following expression.
Correction to standard pressure -
vpm = ppm x standard pressure (abs)
measured pressure (abs)
where standard pressure is taken as 101 kPascals.
The next stage in the process is to determine the mass concentration. The
conversion at STP uses conversion factors determined as follows:
Conversion to mass concentration -
N=RMM
V
where N = conversion factor
RMM = relative molecular mass of the gas
V = 22.4 (standard volume of an ideal gas)
The conversion factor given below:
Conversion factors (N) -
Molecular mass (RMM) = 12 + 16 = 28
1 vpm = 28/22.4 = 1.25 mg/m
The mass concentration present is calculated as below:
3
mg/m
(STP) = N. vpm
3
1-6
This value is the mass concentration of the gas at STP.
Correction for oxygen and water vapor.
Finally the effects of water vapor and oxygen need to be considered.
Instruction Manual
IM-106-5500, Original Issue
August 2005
CCO 5500
Since the vpm measurement is already normalized for temperature and
pressure, the only further normalization required is for the dilution effects of
water vapor and oxygen. These are straightforward calculations as shown
below:
mg/Nm
3
= mg/m3 (STP) x 20.9 - 0%2 standard x100
20.9 - (0%2 measured) DRY = 100 - H2O%
20.9% is taken as the level of free oxygen in dry air.
NOTE
If the measured O
% is a wet measurement the measured O2 concentration
2
must be corrected to a dry measurement. This is performed automatically by
the software if the measured O
concentration is defined as a wet
2
measurement; where:
(O
% measured) DRY = (O2% measured) WET x 100
2
100 - H2O%
If no correction is required for oxygen then standard O
If no correction is required for water vapor then H
= O2 measured.
2
O% = 0
2
After all these calculations have been performed the resulting measurement
is the effective mass concentration of the pollutant normalized to standard
conditions (in mg/Nm
3
).
Measured conditions -
Where measured values are required (e.g. to calculate rates of emissions)
they need to be recalculated for measured temperature and pressure as
shown below:
3
mg/m
= N.vpm x 273 x measured pressure
T standard pressure
substituting,
vpm = ppm x standard pressure
measured pressure
the measured mass concentration of the gas is:
3
= N.ppm x 273
mg/m
T
Principles of Cross-Duct Gas Analyzers
Cross-duct analyzers work on the basic principle that infrared (IR) energy is
absorbed by particular gases in a manner very specific to the gas.
Although cross-duct analysis will differ from gas to gas, the basic principles
are similar for all measured gases. This section examines the analysis of
carbon monoxide in detail.
1-7
CCO 5500
Figure 1-3. CO IR Absorption Spectrum
Instruction Manual
IM-106-5500, Original Issue
August 2005
Carbon Monoxide IR Absorption Spectrum
Carbon monoxide absorbs IR energy in a band between wavelengths of
approximately 4.5 and 4.9 µm. The absorption spectrum is complex and is
illustrated in Figure 1-3 below.
Absorption (%)
0
4.5 4.6 4.7 4.8 4.9
Wavelength (microns)
Figure 1-4. Comparison of Spectra
However, two other common flue gas constituents - carbon dioxide and water
vapor - also absorb energy within this wave band. Fortunately, at 4.7µm, IR
absorption by each of these gases is at a minimum. Figure 1-4 demonstrates
how the absorption spectra of CO, CO
and water vapor affect wavelengths of
2
between 4.5 and 4.9 µm.
Absorption Spectra of CO, CO
and Water Vapor
2
By using a narrow band pass filter which only passes IR energy at
wavelengths of around 4.7µm, correctly designed CO analyzers are able to
ignore the effects of water vapor and CO
. (The filter characteristics are
2
shown in Figure 1-4). No other flue gases absorb IR energy in this band.
Filter
Limits
CO
2
HO
2
Absorption (%)
1-8
0
4.5 4.6 4.7 4.8 4.9
Wavelength (microns)
Instruction Manual
IM-106-5500, Original Issue
August 2005
Figure 1-5. Transmissivity of CO
CCO 5500
Transmissivity of CO Within the 4.7µm Band
The transmission through the gas of the IR energy at about 4.7µm is affected
by the concentration of CO. Figure 1-5 illustrates how the energy within the
selected band varies with CO concentration.
Transmission (%)
0
CO Concentration (ppm.m)
The shape of this curve is fixed by the characteristics of the 4.7µm filter - it
cannot change, and the curve is practically flat at CO concentrations of above
10,000 ppm.meters. A cross-duct monitor effectively measures CO molecules
in its optical path, so the same concentration of CO will have a greater effect
across a large measurement path than a small measurement path. The term
ppm.meters is the concentration of CO within the duct multiplied by the gas
path length over which it has been measured.
Carbon Monoxide Calculation
CCO 5500 Analyzers make two measurements of IR energy in the narrow
band around 4.7µm. Both measurements are made after the beam has
passed through the gas to be measured. One, however, also passes through
a cell containing pure CO (the gas cell shown in Figure 1-2). This absorbs all
the energy capable of being absorbed by CO and provides a reference that is
unaffected by any CO in the duct, but will be affected by any other material
(e.g. dust) which reduces the energy received from the transmitter, in exactly
the same way as the other beam.
The second beam does not have such a cell in front of it and, as such, is very
sensitive to changes in CO within the duct.
The measurement of CO is calculated from a parameter Y, where:
Y=G-K.D2/D1
and D2 = the live detector output
D1 = the reference detector output
K = a composite gain factor which takes
account of all optical and electronic gains
G = scaling factor
1-9
CCO 5500
Figure 1-6. Calibration Curve
Instruction Manual
IM-106-5500, Original Issue
August 2005
Calibration
Figure 1-6 shows the parameter Y against the CO concentration.
0.14
0.12
0.10
0.08
Parameter Y
0.06
0.04
0.02
0
A
CO
In Duct
12
4
567891011123
CO ppm.m (x1000)
Practical
Limit
Calibration
Point
B
Calibration Point
Including
CO in Duct
This is the calibration curve for the instrument and is opposite in shape to the
transmissivity curve shown in Figure 1-5. Each is fixed by the characteristics
of the 4.7µm filter and cannot change. Rosemount Analytical analyzers make
full use of this scale shape to provide an easily attainable calibration point.
It is not necessary to calculate K because we know that when the constant K
is correct:
Y is 0 when the CO level is 0
If there is any drift in the measurement, it can only be due to a change in
some optical or electronic gain and can always be corrected by setting Y to
zero when the CO level is zero.
1-10
In practice, however, it is not always possible to produce a zero CO level, but
if we consider the calibration curve, we can see that:
if Y = 0 when CO = 0
then Y = a when CO = b
We can also see from Figure 1-6 that at high CO levels, the parameter Y
becomes completely insensitive to variable CO levels in the duct, such that:
Y = a when the CO >
By making Y = a when CO >
b
b, Y = 0 when CO = 0 and all these errors are
eliminated.
A gas cell containing pure carbon monoxide can be introduced into the IR
beam at the source. This cell represents a value of 10,000 ppm.meters and
provides a reference point for the calibration of the instrument. Any further CO
in the duct will have negligible effect on the reference point because the
calibration curve is flat at these high concentrations of CO. Well-designed
cross-duct analyzers introduce this gas cell regularly - every few seconds - to
continuously check and (if necessary) modify their zero position.
Instruction Manual
IM-106-5500, Original Issue
August 2005
SPECIFICATIONS
CCO 5500
CCO 5500 Specifications
Span* Selectable from 0-100 ppm to 0-10,000 ppm,
within the range 200 to 6,000 ppm.meters at
STP
Display Units ppm
Averaging Four averages selectable from
Accuracy ±2% of measurements or
Outputs
Analog
High Alarm
Data Valid
Inputs
Oxygen
Temperature
Pressure
Plant Status Contact
Serial Port For remote instrument operation,
Path Length 1.6 to 26 ft (0.5 to 8 m)
Flue Gas Temperature 1202oF (0 to 650oC)
Construction Cast aluminium, fully sealed to IP65
Transmitter Electrically heated silicon nitride cylinder
Detector Lithium tantalate pyro-electric detector
Ambient Temperature Limits -4oF to 158oF (-20oC to 70oC)
Power Requirements 85-132/170-264V AC, 50/60 Hz, 50VA
Air Purge Consumption 2.2 cfm @ 14.9 psi (1 liter/sec @ 1 bar)
3
mg/m
(measured)
3
mg/Nm
(normalized)
10 seconds to 30 days
±5 ppm whichever is greater
4-20 mA isolated, 500S max.
Volt-free contact, 10A @ 250V
Volt-free contact, 10A @ 250V
4-20 mA
4-20 mA
4-20 mA
Volt-free Contact
normalizing inputs and outputs
(compressed air)
11 cfm (5 liter/sec) (blower air)
NOTE:
*The range of the output span is quoted in ppm.meters. To obtain the
minimum and maximum span for your application, divide these figures by the
path length in meters.
1-11
CCO 5500
Instruction Manual
IM-106-5500, Original Issue
August 2005
1-12
Instruction Manual
IM-106-5500, Original Issue
August 2005
Section 2 Installation
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2
Electrical Supply Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2
Unpacking the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . page 2-3
Selecting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-3
Duct Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-4
Isolating Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-6
Air Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-6
Transmitter and Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-6
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-7
Signal Processor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-8
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-9
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-9
CCO 5500
Before installing this equipment, read the “Safety instructions for the wiring and installation
of this apparatus” in Appendix A. Failure to follow safety instructions could result in serious
injury or death.
Install all protective equipment covers and safety ground leads after installation. Failure to
install covers and ground leads could result in serious injury or death.
Before making any electrical connections, make sure the AC power supply is first switched
off. Failure to do so could cause personal injury or even death. Make sure that the voltage
and frequency of the AC supply match the designations on the analyzer component tags.
http://www.raihome.com
CCO 5500
Instruction Manual
IM-106-5500, Original Issue
August 2005
SAFETY CONSIDERATIONS
The mains power is supplied to the whole system via the power supply.
During installation, DO NOT connect the system to the mains until all units are
in place and fully wired up. Keep the isolating valves, if used, CLOSED. The
compressed air (to be supplied to the air purges) must be turned OFF until the
full installation is complete. If any servicing or rewiring is to be performed
ensure that the power supply is isolated. For configuration the system needs
to have power, compressed air and the isolating valves open.
ELECTRICAL SUPPLY DATA
AC Supplies
The CCO 5500 may be powered from either 85-132V AC/170-264V AC at
47-440 Hz. A switch within the power supply unit selects the input voltage and
an internal 2A/20 mm fuse protects the instrument.
Voltage fluctuations within the above ranges are tolerated without loss of
performance and the total power requirement is less than 50VA.
Outputs Three forms of output are provided:
1. A selectable, fully isolated, current output (either 4-20 mA or 0-20 mA),
maximum load 500S - taken from the signal processor.
2. Single pole change-over relays (rating 250V at 10A), for:
• Alarm triggering at a selectable gas threshold
• Data valid indication, operating under power failure and any
equipment fault condition - see the basic fault finding section for
further details - contact outputs are taken from the power supply unit
3. 4-wire serial data link for 2-way communication with a central processor
- taken from the signal processor unit.
Normalizing Inputs Pressure, temperature, and oxygen values can be held to normalize the
calculated gas value to standard conditions. These values may be read by the
instrument using the following methods:
1. Fixed value from the key pad.
2. 4-20 mA outputs from measurement transducers - the ranges represented by these inputs are set from within the processor - inputs are taken to the signal processor.
3. If the analyzer is part of an integrated system, the serial data line can carry the normalizing values.
Plant Status Input The plant status input facility is available to prevent the rolling average stacks
being diluted by measurements made during periods where the plant is shut
down. It is governed by one of three choices; a serial input (from an integrated
system), the logic input (terminals PS1 and PS2 in the signal processor) and
multiple. Multiple has five options; temperature, oxygen, water vapor
thresholds, and logic input. It is set in Mode 5. All these are described in more
detail later in this manual.
In normal operation (plant operating), the plant status will register as ON.
However, if the plant status condition is broken, the status will change to OFF
and the averaging stacks (minutes, hours, days) will not be updated.
2-2
Instruction Manual
IM-106-5500, Original Issue
August 2005
CCO 5500
NOTE
For normal operation terminals PS1 and PS2 must not be linked together.
CABLE REQUIREMENTS 1. Power supply to signal processor - 7-core, shielded, multi-stranded,
2
.
UNPACKING THE EQUIPMENT
6/0.2 mm. 0.5 mm
NOTE
Although screened cable is specified for the interconnecting cable, it is not
necessary for the cable to be grounded.
2. Current loop output - any suitable 2-conductor cable - maximum length depends on keeping output load within the 500S maximum load requirement.
3. Contact outputs - any 2-conductor cable capable of supplying the power to the warning device/relay etc. 250V, 10A maximum.
4. A.C. power - any suitable 3-conductor power cable capable of transmitting 50VA.
5. Serial data link (if required) - twin twisted pair shielded cable - see IEM Communications Manual for further details (Doc. ID 0006/6).
6. Analog inputs - any suitable 2-conductor cable - Rosemount instruments have an internal impedance of 240S for these inputs.
A typical Rosemount Analytical CCO 5500 Carbon Monoxide (CO) Analyzer
should contain the following items. Record the part number, serial number,
and order number for each component of your system.
1. Transmitter with 33 ft (10 m) of cable and air purge.
2. Receiver with 33 ft (10 m) of cable and air purge.
3. Signal processor.
4. Power supply.
5. Site mounting flange (2).
6. Gaskets (4), selected screws and washers.
SELECTING LOCATION The equipment is designed for mounting on boiler ducting or stacks in
positions open to the weather. It is fully sealed and requires no further
enclosures or protection. The specific location of the instrument will depend
on the application and user requirements, but the following considerations
should be made when choosing a site.
2-3
CCO 5500
1. The site must be accessible at both sides of the duct for servicing the
transmitter and receiver.
2. The site should be as free from extremes of temperature and vibration
as possible - permissible ambient temperature range -4
o
(-20
C to +70oC).
3. Flue gas temperatures should not exceed 572
measurement - at higher temperatures instrument accuracy will
deteriorate.
4. There must be an uninterrupted sight path available between the transmitter and the receiver.
5. The maximum cable length allowed between the power supply and the transmitter is 33 ft (10 m).
6. The maximum total cable length between the power supply and the receiver is 82 ft (25 m).
See Figure 1-1 for an illustration of a typical system arrangement.
Points to Consider Path Length
• Too long [>26 ft (8 m)] - low energy available.
• Too short [<1.6 ft (0.5 m)] - optical problems.
Instruction Manual
IM-106-5500, Original Issue
August 2005
o
F to 158oF
o
F (300oC) at the point of
Flue Gas Temperature
• Too low (<dewpoint) - potential water droplets.
• Too high [>662
o
F (>300oC)] - reduced sensitivity.
Ambient Temperature
• Too low [< -4
• Too high [>158
o
F (< -20oC)] - condensation on lenses.
o
F (+70oC)] - potential instrument problems.
Measurement Range
• Minimum range depends on acceptable measurement uncertainty,
which is 10 ppm.meters, e.g. for the level of uncertainty to be below 2%
of range, the minimum range would be 500 ppm. meters.
Note: 10 ppm CO = 12.5 mg/m
3
• For increased sensitivity (reduced uncertainty of measurement) the
path length must be maximized.
• Maximum ranges - 6000 ppm.meters.
Note: To correct ppm.meters to effective ppm, divide by the pathlength.
DUCT WORK The transmitter and receiver units are mounted on a site mounting flange,
Figure 2-1, on opposite sides of the duct. To protect operators, it is
recommended that an isolating valve is used for ducts that operate at a higher
than atmospheric pressure.
2-4
A stand-off pipe [nominal bore 3 in. (75 mm) - not supplied] should be used
between the duct and the site mounting flange. The pipe should be long
enough to clear the equipment from any duct lagging; it also helps to insulate
the equipment from any high duct temperatures.
Instruction Manual
IM-106-5500, Original Issue
August 2005
Figure 2-1. Site Mounting Flange
CCO 5500
A hole should be cut on either side of the duct to be measured; these holes
should accept a 'slip fit' with the stand-off pipe. The stand-off pipe should now
be welded into each hole and a mounting flange welded to each pipe with the
tapped holes positioned as shown in Figure 2-1 (it may be easier to weld the
pipe and the flange together before they are fixed to the duct). To avoid
vibration and movement, it may be necessary to fit spreader plates or bracing
fillets.
Alignment is satisfactory if one orifice can be clearly seen when viewed
through the stand-off pipe on the other side of the duct. It is suggested that
the stand-off pipe is 'tacked' on to the duct and the alignment checked visually
before a complete weld is made. The alignment of these holes is not critical,
as the integral adjustable mount compensates for up to 4
Duct Wall
o
of misalignment.
Lagging
Site Mounting Flange
Bracing Fillets
Stand-Off Pipe (if used)
3 in.(75 mm) dia. nominal
6.5 in.
(165 mm)
4 Holes M8
on 4.92 in. (125 mm)
Bolt Circle
2-5
Instruction Manual
IM-106-5500, Original Issue
CCO 5500
August 2005
ISOLATING VALVES If isolating valves are used they mount directly onto the site mounting flanges.
AIR PURGE The air purge mounts on the isolating valve. They are mounted by separating
the front flange from the air purge by unscrewing the four locking nuts. A
'snout' and o-ring arrangement locate into the front flange; work the two apart
carefully. The front flange should now be bolted to the isolating valve if used
or site flanges with a rigid gasket fitted between them, using the four
countersunk screws provided.
NOTE
Before mounting the air purges, ensure that air is supplied to the air purge
unit. If this precaution is not observed then the air purge and the
optical surfaces may be severely contaminated.
The adjustable flange is then positioned on the front flange, taking care that
the o-ring seal and 'snout' locate smoothly into the central aperture. This is
then secured by the four locking nuts that screw down onto the adjustable
flange. The arrangement should now appear as shown in Figure 2-2.
Figure 2-2. Valve and Purge Arrangement
TRANSMITTER AND RECEIVER
Locking Nuts
Valve Handle
Air Purge
Pressure Regulator
Assembly
Isolation Valve
(if used)
Site Mounting
Flange
Adjusting Nuts
Rigid
Gasket
The transmitter and receiver attach to the rear face of the air purge with a
flexible gasket fitted between them, using the M6 x 20 hexagon head screws
provided (see Figure 2-3). A locating dowel ensures that the units can only be
attached to the air purge in one position - make sure this locates correctly.
2-6
NOTE
Before mounting the transmitter and receiver, ensure that air is supplied to the
air purge unit. If this precaution is not observed then the air purge and the
optical surfaces may be severely contaminated.
Instruction Manual
IM-106-5500, Original Issue
August 2005
Figure 2-3. Analyzer Head Arrangement
Air Purge
Hexagon
Head Screws
CCO 5500
Flexible Gasket
Transmitter or
Receiver
AIR SUPPLY The purpose of the air purge is to keep the windows of the transmitter and the
receiver clean. Air may be supplied by one of three methods:
1. Negative pressure duct.
If the duct across which the instrument is measuring operates at a
negative pressure under all firing conditions, the air purge inlets may be
simply left open and the negative draft in the duct allowed to draw in
ambient air.
NOTE
For positive pressure ducts, they must be supplied with either compressed air,
or air from a blower.
2. Compressed air.
Using a fine flow regulator and filter, compressed air may be used to
provide the low flow required - an air supply of 14.7 psi (1 bar) is
required and the consumption is 2.2 cfm (1 liter/second) per purge.
3. Blower air.
A blower may be used to provide the air to the air purge - customers
may specify their own blower - it should be able to deliver 11 cfm (5
liters/second) per purge against the working pressure of the duct Rosemount Analytical can specify a blower if required.
2-7
CCO 5500
Instruction Manual
IM-106-5500, Original Issue
August 2005
SIGNAL PROCESSOR UNIT
Figure 2-4. Signal Processor Unit/Power Supply Unit Mounting Detail
Cover Seal - Note that the
mounting holes are beyond
the extent of the seal
Assembled Box
110 mm Deep
9.1 in.
(230 mm)
Enough cable is supplied to mount the signal processor up to 33 ft (10 m)
from the receiver. To mount the signal processor (Figure 2-4), first remove the
cover by loosening the four captive screws, unplug the ribbon cable at the
connector on the lid PCB. Note that the processor case has a hinged lid. The
case is then secured to a firm support by use of the four mounting holes found
in the four corners of the case, outside the sealing rim. Since the mounting
holes are located outside the seal of the case, it is not necessary to seal the
mounting holes after installation, nor is it necessary to remove the circuitry
from the case for installation.
7.1 in.
(180 mm)
Cover
Base
4 Holes for M6
Mounting Screws
7.1 in.
(180 mm)
7.9 in.
(200 mm)
Approx. 6 in. (150 mm)
free space required
below box for cables
Cable Gland Entry
Blanking Plugs
2-8
Instruction Manual
IM-106-5500, Original Issue
August 2005
CCO 5500
POWER SUPPLY UNIT Enough cable is supplied to mount the power supply up to a maximum of 33 ft
(10 m) from the transmitter. A maximum total cable length of 82 ft (25 m) may
be used to link the power supply to the receiver. These are the maximum
permitted lengths of cable and must not be exceeded.
Dimensions and mounting hole locations are identical to the signal processor
and are illustrated in Figure 2-4.
ELECTRICAL CONNECTIONS
Wiring should only be undertaken by a qualified technician.
Ensure that the power supply is isolated.
DO NOT switch power on until all installation work is complete and the system is ready for
configuring.
Installation of Cables Decide routing for all non-power cables (both those supplied by Rosemount
Analytical and those sourced locally). Use common routing wherever possible
and install leaving sufficient free-end length to make final connections.
Power cables should be installed separately, using different routes if possible
to reduce the risk of cross interference. Leave sufficient free-end length to
make final connections.
Rosemount supplied cables are provided with ferrite beads fitted to all cores
to protect against interference and should not be modified without consulting
Rosemount.
Cable Connections Overall system connections are illustrated in Figure 2-5.
2-9
CCO 5500
Figure 2-5. System Cable Connections
TO SIGNAL
PROCESSOR
MOTOR DRIVE
REFERENCE WAVE
0V
+12V
ALARM CONTACT
DATA VALID
12345
MOTOR DIRECTION
6
7
2
0.5 mm
PVC COPPER
BRAID SCREEN
COMMON
W1
CABLE
8 CORE
INTERCONNECT
N/C
C1
COMMON
W2
N/O
O1
DATA VALID CONTACT
N/O
O2
ALARM CONTACT
N/C
C2
0V
DATA VALID
+12V SUPPLY
ALARM SIGNAL
12345
TO POWER
SUPPLY
MOTOR DRIVE
REFERENCE WAVE
6
MOTOR DIRECTION
OXYGEN
7
Instruction Manual
IM-106-5500, Original Issue
August 2005
4-20 mA (IN)0VTEMPERATURE
4-20 mA (IN)0VPRESSURE
4-20 mA (IN)
INPUTS
0V
13
PS1
PLANT STATUS
PS2
INPUT
+mA
ANALOG
8
9
101112
NORMALIZING
0mA
OUTPUT
POWER SUPPLY
8
BLUE
YELLOW
PVC COPPER
BLUE
YELLOW
9
101112
PURPLE
BLACK/WHITE
RED/BROWN
2
0.5 mm
8 CORE
BRAID SCREEN
PURPLE
BLACK/WHITE
RED/BROWN
SCREEN NOT TO BE GROUNDED
AT POWER SUPPLY
L
E
N
BLUE
GREEN/YELLOW
BROWN
50-60Hz
110V/220V
SIGNAL PROCESSOR
16
RED
RED
171819
BLACK
WHITE
BLUE
2
0.5 mm
PVC COPPER
BRAID SCREEN
BLACK
WHITE
BLUE
20
21
GREEN
YELLOW
PURPLE
8 CORE
SCREEN NOT TO BE GROUNDED
SCREEN
GREEN
YELLOW
PURPLE
TX+
22
AT SIGNAL PROCESSOR
23242526272829
SERIAL DATA
TX-
RX+
RX-
RX-
SERIAL DATA
RX+
TX-
TX+
30
2-10
TRANSMITTER
MOTOR DIRECTION
MOTOR DRIVE
REFERENCE WAVE
0V TO SOURCE
12V TO SOURCE
SCREEN
RECEIVER
+12V SUPPLY
0V
D1 SIGNAL
SIGNAL 0V
D2 SIGNAL
TEMP INPUT
SOLENOID DRIVE
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