Rosemount CCO 5500 Carbon Monoxide (CO) Analyzer-Rev 1.0 Manuals & Guides

Rosemount™ CCO 5500

Carbon Monoxide (CO) Analyzer

Reference Manual

00809-0100-4550, Rev AA

June 2018

Essential instructions

Read this page before proceeding!

EmersonTM designs, manufactures, and tests its RosemountTM 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 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 this product. If this instruction manual is not the correct

manual, call 1-855-724-2638, and we will provide the requested manual. Save this 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 your equipment as specified in the installation instructions of the appropriate 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 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 people, to prevent electrical shock and personal injury.

The information contained in this document is subject to change without notice.

Warranty

RosemountTM warrants that the equipment manufactured and sold by it will, upon
shipment, be free of defects in workmanship or material. Should any failure to conform to
this warranty become apparent during a period of one year after the date of shipment,
Rosemount shall, upon prompt written notice from the purchaser, correct such
nonconformity by repair or replacement, F.O.B. factory of the defective part or parts.
Correction in the manner provided above shall constitute a fulfillment of all liabilities of
Rosemount with respect to the quality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR
IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE).

The remedy(ies) provided above shall be purchase'rs sole remedy(ies) for any failure of Rosemount to comply with the warranty
provisions, whether claims by the purchaser are based in contract or in tort (including negligence).

Rosemount does not warrant equipment against normal deterioration due to environment. Factors such as corrosive gases and
solid particulates can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the
warranty period.

Equipment supplied by Rosemount but not manufactured by it will be subject to the same warranty as is extended to Rosemount by
the original manufacturer.

At the time of installation, it is important that the required services are supplied to the system and that the electronic controller is
set up at least to the point where it is controlling the sensor heater. This will ensure that, should there be a delay between
installation and full commissioning, the sensor being supplied with ac power and reference air will not be subjected to component
deterioration.

Preface

The purpose of this manual is to provide information concerning the components,
functions, installation, and maintenance of the RosemountTM CCO 5500.

Some sections may describe equipment not used in your configuration. Become thoroughly familiar with the operation of this
module before operating it. Read this reference manual completely.

Definitions

The following definitions apply to WARNINGS, CAUTIONS, and NOTICES found throughout
this publication.

WARNING!

Highlights an operation or maintenance procedure, condition, statement, etc. that if not strictly observed, could result in injury,
death, or long-term health hazards of personnel.

CAUTION!

Highlights an operation or maintenance procedure, practice, condition, statement, etc. that if not strictly observed, could result in
damage to or destruction of equipment or loss of effectiveness.

NOTICE

Highlights an essential operating procedure, condition, or statement.

Symbols

Earth (ground) terminal

:

Protective conduit or terminal

:

Risk of electrical shock

:

Warning: Refer to Instruction Manual

:

Contents

Contents

Chapter 1 Description and specifications ..........................................................................................1

1.1 Component checklist ..................................................................................................................... 1

1.2 Overview ........................................................................................................................................3

1.3 System description .........................................................................................................................3

1.4 Specifications .................................................................................................................................5

1.5 Rosemount™ CCO 5500 ordering information ................................................................................ 6

Chapter 2 Install ...............................................................................................................................7

2.1 Unpack the equipment ...................................................................................................................7

2.2 Safety considerations ..................................................................................................................... 7

2.3 Cable requirements ........................................................................................................................8

2.4 Selecting location ...........................................................................................................................8

2.4.1 Points to consider ............................................................................................................9

2.5 Mechanical installation ...................................................................................................................9

2.5.1 Mount flange assemblies ............................................................................................... 10

2.5.2 Isolating valves .............................................................................................................. 11

2.5.3 Purge air supply .............................................................................................................12

2.5.4 Air purge units ...............................................................................................................13

2.5.5 Source and receiver units ...............................................................................................14

2.5.6 Control unit ................................................................................................................... 15

2.5.7 Power supply unit .......................................................................................................... 16

2.6 Electrical data ...............................................................................................................................17

2.6.1 AC supplies ....................................................................................................................17

2.6.2 Outputs .........................................................................................................................17

2.6.3 Normalizing inputs ........................................................................................................ 17

2.6.4 Plant status input ...........................................................................................................17

2.7 Electrical connections .................................................................................................................. 18

2.7.1 Installation of cables ......................................................................................................19

2.7.2 Cable connections ......................................................................................................... 19

Chapter 3 Configuration and startup .............................................................................................. 25

3.1 Introduction .................................................................................................................................25

3.2 Safety considerations ................................................................................................................... 25

3.3 Power up the Rosemount™ CCO 5500 Analyzer ............................................................................ 25

3.4 Alignment .................................................................................................................................... 26

3.5 Detector levels ............................................................................................................................. 29

3.5.1 Receiver gain adjustment .............................................................................................. 30

3.5.2 Control unit gain adjustment .........................................................................................31

3.6 Source adjustments ..................................................................................................................... 33

3.6.1 Source intensity .............................................................................................................33

3.6.2 Chopper frequency ........................................................................................................34

3.7 Set up mode .................................................................................................................................35

3.7.1 Enter security code ........................................................................................................ 36

3.7.2 Set averages .................................................................................................................. 36

3.7.3 Configure O/P ................................................................................................................37

3.7.4 Parameters ....................................................................................................................40

3.7.5 Normalization ................................................................................................................43

Reference Manual i

Contents

3.7.6 Reset averages ...............................................................................................................46

3.7.7 Calibrate ........................................................................................................................46

3.8 Current output calibration ............................................................................................................50

Chapter 4 Operation ...................................................................................................................... 51

4.1 Introduction .................................................................................................................................51

4.1.1 Measurement ................................................................................................................ 51

4.1.2 Calibration .....................................................................................................................52

4.2 Startup and operation .................................................................................................................. 52

4.3 Modes of operation ...................................................................................................................... 52

4.4 Keypad operation .........................................................................................................................53

4.5 Menu tree .................................................................................................................................... 53

4.6 Operating mode ...........................................................................................................................55

4.7 Parameters ...................................................................................................................................56

4.7.1 Identification ................................................................................................................. 56

4.7.2 Parameters .................................................................................................................... 56

4.7.3 Averages ........................................................................................................................57

4.7.4 Output ...........................................................................................................................57

4.7.5 Alarm .............................................................................................................................57

4.7.6 Plant status ....................................................................................................................57

4.8 Normalization .............................................................................................................................. 57

4.9 Diagnostic mode ..........................................................................................................................58

4.9.1 Detector outputs ........................................................................................................... 58

4.9.2 Modulation (chopper motor) frequency ........................................................................ 59

4.9.3 YVals and CO ppm ......................................................................................................... 59

4.9.4 Calibration data ............................................................................................................. 60

4.9.5 Fault condition .............................................................................................................. 60

4.10 Set up mode .................................................................................................................................61

4.10.1 Enter security code ........................................................................................................ 61

4.10.2 Set averages .................................................................................................................. 62

4.10.3 Configure O/P ................................................................................................................63

4.10.4 Parameters .................................................................................................................... 65

4.10.5 Normalization ................................................................................................................69

4.10.6 Reset averages ...............................................................................................................71

4.10.7 Calibrate ........................................................................................................................ 72

4.11 Check Cell mode .......................................................................................................................... 76

4.12 Shutdown procedure ................................................................................................................... 76

4.13 Routine checks .............................................................................................................................76

4.13.1 Notes for using a Rosemount™ check cell .......................................................................76

4.13.2 Alarms and emergency conditions .................................................................................79

4.13.3 Emergency shutdown procedure ................................................................................... 79

4.13.4 Isolation procedure ........................................................................................................79

Chapter 5 Maintenance .................................................................................................................. 81

5.1 Preventative maintenance ........................................................................................................... 81

5.1.1 Cleaning windows ..........................................................................................................81

5.2 Corrective maintenance ............................................................................................................... 82

5.2.1 Replace heater element ................................................................................................. 82

5.2.2 Replace chopper motor assembly .................................................................................. 84

5.2.3 Replace source unit gas cell ........................................................................................... 86

ii Rosemount CCO 5500

Contents

5.2.4 Replace receiver unit gas cell ......................................................................................... 87

5.2.5 Electronics ..................................................................................................................... 88

5.3 Adjust span factor ........................................................................................................................ 88

5.3.1 Reset span factor ........................................................................................................... 89

Chapter 6 Troubleshooting ............................................................................................................ 91

6.1 Finding faults with the keypad ......................................................................................................91

6.1.1 Data valid LED out ..........................................................................................................91

6.2 Troubleshooting tables ................................................................................................................ 92

6.3 Component tests ......................................................................................................................... 96

6.3.1 Heater cartridge ............................................................................................................ 96

6.3.2 Chopper motor ..............................................................................................................96

6.4 LED indications .............................................................................................................................97

6.5 Test points ................................................................................................................................... 98

Chapter 7 Spare parts ...................................................................................................................101

Appendices and reference

Appendix A Theory of operation ......................................................................................................103

A.1 Infrared source unit .................................................................................................................... 103

A.2 Infrared receiver unit ..................................................................................................................104

A.3 Control unit ................................................................................................................................105

A.4 Power supply unit .......................................................................................................................105

A.5 Air purge .................................................................................................................................... 105

A.6 Isolating valves ...........................................................................................................................105

A.7 Principles and modes of operation ............................................................................................. 106

A.7.1 Calculation of gas concentration ................................................................................. 106

A.7.2 Error compensation ..................................................................................................... 106

A.7.3 Calculation sequence ...................................................................................................107

A.7.4 Normalization equations ............................................................................................. 107

A.7.5 Principles of cross-duct gas analyzers .......................................................................... 109

Appendix B Return equipment to the factory .................................................................................. 113

Reference Manual iii

Contents

iv Rosemount CCO 5500

Description and specifications

1 Description and specifications

1.1 Component checklist

A typical Rosemount™ CCO 5500 Carbon Monoxide Analyzer should contain the items
shown in Figure 1-1. Record the part number, serial number, and order number for your
system.

Reference Manual 1

Description and specifications

Typical System PackageFigure 1-1:

A. Control unit
B. Quick Start Guide
C. Power supply
D. Hardware
E. Receiver
F. Interconnect cable
G. 33 ft, (10 m) cables
H. Source
I. Gaskets (4)

Also, use the product matrix in Section 1.5 to compare your order number against your
unit. Ensure the features and options specified by your order number are on or included
with the unit.

2 Rosemount CCO 5500

1.2 Overview

Rapid advances in design of across the duct infrared gas analyzers have led to the general
acceptance of this technique for monitoring gas levels in flue gases of power generation
boilers and large industrial process steam boilers.

The Rosemount™ CCO 5500 Carbon Monoxide (CO) analyzer is designed to operate on
duct widths of less than 26 ft. (8 m) at flue gas temperatures up to 572 °F (300 °C).

NOTICE

The instrument can achieve temperatures up to 1200 °F (650 °C), but degradation in instrument
accuracy will occur.

The rugged construction makes installation extremely simple, and through the use use of
microprocessor technology, the Rosemount CCO 5500 has many advanced features:

• Serial data facility to allow communication between analyzers and a central data

logging station.

• User-definable output in either mg/m3, mg/Nm3, or ppm.

• 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 off periods.

Description and specifications

1.3

System description

The Rosemount

• An infrared source unit to project a beam of infrared radiation across the duct.

• A receiver to measure radiation.

• A power supply unit to provide the necessary power rails.

• A control unit to compute the gas concentration from the signals provided by the

receiver unit.

Each of these units is designed to be rugged and flexible. They are all fully sealed to IP65
standards and are suitable for outside mounting without the need for further
weatherproof enclosures.

™

CCO 5500 Analyzer consists of four items (Figure 1-2):

Reference Manual 3

Description and specifications

Typical System LayoutFigure 1-2:

A. Source
B. Air purge
C. Site mounting flange
D. Receiver
E. Pressure regulator
F. Purge air
G. Isolation valve (by customer if used)
H. Cable 33 ft. (10 m) standard (by Rosemount)
I. Control unit
J. Analog outputs, normalizing inputs, and serial data port
K. AC power in and relay contact outputs
L. Power supply unit

NOTICE

The maximum cable length allowed between the power supply and the receiver is 82 ft (25 m).
The maximum cable length allowed between the power supply and the transmitter is 33 ft (10 m).

4 Rosemount CCO 5500

1.4 Specifications

System Measurement SpecificationsTable 1-1:

Span Selectable 0-100 ppm to 0-10,000 ppm within

Accuracy ±2% of measurement or ±5 ppm, whichever is

Path length 1.6 to 26.2 ft. (0.5 to 8 m)

Process temperature range 32 to 1202 °F (0 to 650 °C)

Display units ppm

Averaging Four averages selectable from 10 sec to 30 days

Environmental SpecificationsTable 1-2:

Description and specifications

the range of 200 to 6,000 ppm.m

greater

mg/m3 (measured)

mg/Nm3 (normalized)

Material of construction Cast aluminum, fully sealed to IP65

Ambient temperature limits -4 to 158 °F (-20 to 70 °C)

Installation SpecificationsTable 1-3:

Probe mounting 6.5 in. (165 mm) flange with 4.9 in. (125 mm)

bolt circle

Inputs Temperature: 4 - 20 mA

Pressure: 4 - 20 mA

Plant status dry contact relay

Outputs Analog 4 - 20 mA isolated, 500 Ω max.

Power requirements 85-132/170-264 Vac, 50/60 Hz, 50 VA

Air purge consumption l liter/sec at 1 bar (compressed air)

5 liter/sec (blower air)

Reference Manual 5

Description and specifications

1.5 Rosemount™ CCO 5500 ordering information

Model Description

CCO 5500 Carbon Monoxide Analyzer - across-the-stack

Level 1 power requirements

01 110/220 Vac, 50/60 Hz

Level 2 control module display/keypad

01 English

Level 3 calibration options

00 None

01 Calibration check cell and holder

6 Rosemount CCO 5500

2 Install

WARNING!

Before installing this equipment, read Essential Instructions. Failure to follow safety instructions
could result in serious injury or death.

WARNING!

ELECTRICAL HAZARD
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.

WARNING!

ELECTRIC SHOCK
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.

Install

2.1 Unpack the equipment

™

CCO 5500 Carbon Monoxide (CO) Analyzer should contain the

2.2

A typical Rosemount
following items.

Refer to Figure 1-1 for an illustration of each of these components. Record the part
number, serial number, and order number for each major component of your system.

1. Source with 33 ft. (10 m) of cable and air purge

2. Receiver with 33 ft. (10 m) of cable and air purge

3. Interconnect cable 3 ft. (0.91 m)

4. Control unit

5. Power supply

6. Gaskets (four)

7. Selected screws and washers

Safety considerations

Power is supplied to the whole system via the power supply unit. During installation, do
not connect the system to the facility power source until all units are in place and fully
wired. If used, keep the isolating valves closed. You must turn off the compressed air

Reference Manual 7

Install

supplied to the purges until the full installation is complete. If you do any servicing or
rewiring, ensure that the power supply is isolated. During configuration, the system
requires electrical power, compressed air, and open isolating valves.

2.3 Cable requirements

1. Power supply to signal processor - seven-core, overall screen, multi-stranded, 6/0.2
mm. 0.5 mm2.

NOTICE

Although shielded cable is specified for the interconnecting cable, it is not necessary to
ground the cable.

2. Current loop output - any suitable two-conductor cable, maximum length depends
on keeping output load within the 500 ohm maximum load requirement.

3. Contact outputs - any two-conductor cable capable of supplying the power to the
warning device/relay, etc. 250 V, 10 A maximum.

4. A.C. power - any suitable three-conductor power cable capable of transmitting 50
VA.

5. Serial data link (if required) - twin twisted pair shielded cable.

6. Analog inputs - any suitable two-conductor cable; Rosemount™ instruments have an
internal impedance of 240 ohms for these inputs.

2.4

Selecting location

Rosemount
the weather. The instrument is fully sealed and requires no further enclosures or
protection. The specific location of the instrument depends on the application and user
requirements. Consider the following when choosing a site.

Refer to Figure 1-2 for a typical system arrangement.

1. The site must be accessible at both sides of the duct for servicing the source and

2. The site should be as free from extremes of temperature and vibration as possible.

3. Flue gas temperatures should not exceed 572 °F (300 °C) at the point of

4. There must be an uninterrupted sight path available between the source and

™

designed the equipment for mounting on boiler ducting or stacks open to

receiver.

Permissible ambient temperature range is -4 °F to 158 °F (-20 °C to 70 °C).

measurment.

NOTICE

The instrument can achieve temperatures up to 1200 °F (600 °C), but degradation in
instrument accuracy will occur.

receiver.

8 Rosemount CCO 5500

5. The maximum cable length allowed between the power supply and the source is 33
ft. (10 m).

6. The maximum cable length between the power supply and the receiver is 82 ft. (25
m).

2.4.1 Points to consider

Path length

1. Too long [> 26 ft (8 m)]: low energy available.

2. Too short [< 1.6 ft (0.5 m): optical problems

Flue gas temperature

1. Too low (< dewpoint): potential water droplets.

2. Too high [> 572 °F (> 300 °C)]: reduced sensitivity.

Ambient temperature

1. Too low [< -4 °F (< -20 °C)]: condensation on lenses.

2. Too high [> 158 °F (> 70 °C)]: potential instrument problems.

Install

2.5

Measurement range

1. Minimum range depends on acceptable measurement uncertainty which is 10 ppm­meters. For example, for the level of uncertainty to be below 2% of range, the
minimum range would be 500 ppm-meters.

NOTICE

10 ppm CO = 12.5 mg/m

2. For increased sensitivity (reduced uncertainty of measurement), the path length
must be maximized.

3. Maximum range is 6,000 ppm-meters.

3

NOTICE

To correct ppm-meters to effective ppm, divide the path length (in meters).

Mechanical installation

The transmitter and receiver units are mounted on a site mounting flange on opposite
sides of the duct. To protect operators, Rosemount™ recommends using an isolating valve
for ducts that operate at a higher than atmospheric pressure.

Use a stand-off pipe [nominal bore 3 in. (75 mm) - not supplied] 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.

Reference Manual 9

Install

2.5.1 Mount flange assemblies

Complete the following steps to mount the flange assemblies for the analyzer.

1. Form two mounting holes on opposite sides of the stack according to the
considerations in Section 2.4.

These holes should accept a slip fit with the stand-off pipe.

2. Weld the stand-off pipes to the site mounting flanges as shown in Figure 2-1.

Site Mounting Flange AssemblyFigure 2-1:

A. Duct wall
B. Lagging
C. Stand-off pipe (if used) 2.95 in. (75 mm) dia. nominal
D. ØM8 hole 4.92 in. (125 mm) BC (4) places
E. Site mounting flange
F. Bracing fillets

3. With the stand-off pipes and site mounting flanges welded together, insert the
mounting flange assemblies into their mounting holes.

4. Position the mounting flange assemblies so the four threaded mounting holes are
located as shown in Figure 2-1.

10 Rosemount CCO 5500

NOTICE

Rosemount™ suggests that you tack weld the stand-off pipe to the duct and check the
alignment visually before making a complete weld.

5. Look through one of the mounting flange assemblies.

If the you can see the orifice across the stack clearly, the alignment is satisfactory.
The alignment of these holes is not critical; an integral adjustable mount can
compensate for up to 4 degrees of misalignment.

6. Weld the assemblies in place.

To avoid vibration and movement, you may need to fit spreader plates or bracing
fillets on the mounting flange assembly as shown in Figure 2-1.

2.5.2 Isolating valves

To protect operators, Rosemount™ recommends that you use customer supplied isolating
valves (Figure 2-2) for ducts that operate at higher than atmospheric pressure. Valve
selection and installation is your responsibility.

Install

Isolating Valve and Air Purge ArrangmentFigure 2-2:

A. Isolating valve (customer supplied)
B. Adjusting nuts
C. Locking nuts
D. Air purge port
E. Pressure regulator assembly
F. Rear flange
G. Front flange
H. Site mounting flange

Reference Manual 11

Install

After the isolating valves are installed in the site mounting flanges, connect the purge air
supply and install air purge units according to the following instructions.

2.5.3 Purge air supply

The purpose of the purge air is to keep the windows of the source and the receiver clean.
Always connect the purge air supply to the air purge units before you install the air purge
units on the process duct. Purge air may be supplied by one of the following three
methods.

Negative pressure duct

If the duct operates at a negative pressure under all firing conditions, you may simply leave
the air purge inlets open and allow the negative draft in the duct to draw in ambient air.

You must supply the air purge units for positive pressure ducts with compressed air or
blower air to prevent contamination of the source and receiver units.

Compressed air

You may use compressed air to provide the air 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. Use a fine
control flow regulator and filter.

Blower air

You may use a blower to provide the air to the air purge. Customers may specify their own
blower. The blower should deliver 11 cfm (5 liters/second) per purge against the working
pressure of the duct.

12 Rosemount CCO 5500

Air Purge MountingFigure 2-3:

A. Site mounting flange or isolating valve flange
B. Adusting nuts
C. Locking nuts
D. Air purge
E. Rear flange
F. Front flange

Install

2.5.4

Air purge units

Use the general procedure that follows to install the air purge units on the site mounting
flanges or on the exposed flanges of the customer supplied isolating valves, if used.

CAUTION!

CONTAMINATION

Always connect and turn on the purge air supply to both air purge units before mounting the
air purge units. Failure to flow purge air may allow the optical surfaces of the source and
receiver units to become severely contaminated.

Procedure

1. Remove the four locking nuts holding the front flange to the rear flange (Figure 2-3).

2. Carefully work and pull the front flange from the air purge unit.

3. Align the four holes on the front flange with the four holes on the site mounting
flange.

4. Fasten the front flange to the site mounting flange with the four countersunk screws
and gaskets provided.

5. Connect and turn on a compressed air or blower air supply to the purge unit. Always
flow purge air before installing an air purge unit on the duct.

Reference Manual 13

Install

6. Install the air purge unit on the front flange as shown.

7. Install and tighten the four locking nuts removed in Step 1.

2.5.5 Source and receiver units

Use the following procedure to install the source and receiver units on the air purge units.

1. Insert a flexible gasket between the air purge unit and the source or receiver unit.

2. Dowel pins (Figure 2-4) ensure that the source and receiver units and the air purge
units mount in a fixed rotary position. Align the dowel pin and dowel pin hole.

Air Purge and Source Unit Mounting FeaturesFigure 2-4:

A. Locking nut
B. Window plate
C. Source
D. Alignment dowel pin hole
E. Threaded screw hole
F. Rear face of air purge

3. Attach the source or receiver to the rear face of the air purge and install the four
screws provided (Figure 2-5).

14 Rosemount CCO 5500

Air Purge and Source Units (Installed)Figure 2-5:

A. Site mounting flange
B. Front flange
C. Gasket
D. Source or receiver
E. Window plate
F. Air purge
G. Rear flange

Install

2.5.6 Control unit

Rosemount™ supplies adequate cableto locate the control unit up to 33 ft. (10 m) from the
receiver. Do not exceed the 33 ft. (10 m) cable length.

1. Loosen the four captive cover screws and remove the cover.

2. Unplug the ribbon cable connector on the cover side.

3. Fasten the control unit to a firm vertical support. Install four mounting screws in the
mounting holes provided.

Refer to Figure 2-6 for mounting dimensions.

Reference Manual 15

Install

Mounting Dimensions for the Control and Power Supply UnitsFigure 2-6:

2.5.7

A. Cover seal - Note that the mounting holes are outside the extent of the seal.
B. Cover
C. Base
D. 4 Holes for M6 mounting screws
E. Cable gland entry blanking page
F. Approx. 6 in. (150 mm) free space required below box for cables
G. Assembled box 4.3 in. (110 mm) deep

NOTICE

The unit mounting holes are located outside the seal. You do not need to seal the
mounting holes after installation or to remove the circuit boards from the unit prior to
mounting.

Power supply unit

Rosemount supplies adequate cableto locate the power supply unit up to 33 ft. (10 m)
from the source unit. You may use a maximum cable length of 82 ft. (25 m) to connect the
power supply unit to the receiver. Do not exceed the 82 ft. (25 m) maximum cable length.

Dimensions and mounting hole locations are identical to the control unit and are shown in

Figure 2-6.

16 Rosemount CCO 5500

2.6 Electrical data

2.6.1 AC supplies

You can power the Rosemount™ CCO 5500 Analyzer from either 85-135 Vac or 170-264
Vac at 50/60 Hz. A switch within the power supply unit selects the input voltage, and an
internal 2 A fuse protects the instrument. The analyzer tolerates voltage fluctuations
within these ranges without losing performance. The total power requirement for the
analyzer is less than 50 VA.

2.6.2 Outputs

Three analyzer outputs are available:

1. Selectable, fully isolated 4-20 mA or 0-20 mA % CO concentration, 500 ohms
maximum load.

2. Single pole, switching relays (rated 250 V, 10 A) for the following outputs:

• Alarm trigger at a selectable gas threshold.

• Data-valid indication active during power failure and any equipment fault

condition. See Chapter 6 for further details.

3. Four-wire serial data link for two-way communication between the control unit and
a distributed control system or other process control system.

Install

2.6.3

2.6.4

Normalizing inputs

The analyzer can hold pressure, temperature, and oxygen values to normalize the
calculated gas value to standard conditions. The instrument may read these values using
the following methods:

1. Fixed value from the keypad.

2. 4-20 mA outputs from measurment transducers. You can set the ranges
represented by these inputs from within the processor. These are analog process
inputs to the control unit.

3. When the analyzer is part of an integrated system, the serial data line can carry the
normalizing values.

Plant status input

The plant status input parameter is available to prevent the rolling average data from
being diluted by measurements made while the plant is shut down. The parameter is
governed by one of three choices:

1. Serial input (from an integrated system)

2. Logic input (terminals PS1 and PS2 in the control unit)

3. Multiple (five variables)

a. Temperature

Reference Manual 17

Install

b. Oxygen

c. Pressure

d. Water vapor

e. Logic input

You can set these parameters in Mode 5. Chapter 4 describes each of these parameters.

During normal operation, the plant status registers as ON. However, if the plant status
input is lost, the status changes to OFF, and the averaging data (seconds, minutes, hours,
days) is not updated.

NOTICE

During normal operation, do not link terminals PS1 and PS2 together.

2.7 Electrical connections

All equipment wiring must conform to local and national codes. Read and observe the
following instructions before making electrical connections.

WARNING!

ELECTRIC SHOCK
Disconnect and lock out power before connecting the power supply to the analyzer.

WARNING!

ELECTRIC SHOCK
Install all protective covers and safety ground leads after installation. Failure to install covers
and ground leads could result in serious injury or death.

WARNING!

ELECTRIC SHOCK
To meet the safety requirements of IEC 1010 (EC requirement) and ensure safe operation of this
equipment, connect to the main electrical power supply through a circuit breaker (min. 10 A)
which will disconnect all current-carrying conductors during a fault situation.This circuit
breaker should also included a mechanically operated isolating switch. If not, then locate
another external means of disconnecting the supply from the equipment close by. Circuit
breakers or switches must comply with a recognized standard, such as IEC 947.

NOTICE

To maintain proper earth grounding, ensure a positive connection exists between the
transmitter housing and earth. The connecting ground wire must be 14 AWG minimum.

18 Rosemount CCO 5500

NOTICE

Line voltage, signal, and relay wiring must be rated for at least 221 °F (105 °C). Make sure that
the voltage and frequency of the AC power supply match the required power specifications.

NOTICE

If metal conduit is used with the power supply unit and/or the source unit, bond the conduit
reliably to protective earth. Grounding points inside the units are not bonded to PE and do not
provide adequate grounding.

2.7.1 Installation of cables

Decide routing for all non-power cables (both those supplied by Rosemount™ and those
sourced locally). Use common routing wherever possible and install leaving sufficient free­end length to make final connections.

Install power cables separately using different routes if possible to reduce the risk of cross­interference. Leave sufficient free-end length to make final connections.

Install

Rosemount supplied cables are provided with ferrite beads fitted to all cores to protect
against interference. Do not modify the cables without consulting Rosemount.

2.7.2 Cable connections

Use the following procedure to make cable connections between the source, receiver,
power supply unit, and control unit.

Figure 2-7 displays a system wiring diagram. Figure 2-8 displays the location of power

supply and control unit connectors, etc.

Reference Manual 19

Install

System Wiring DiagramFigure 2-7:

20 Rosemount CCO 5500

Install

Wiring Connector Locations (Power Supply Board)Figure 2-8:

A. 110/220 Vac power in
B. Data-valid relay contacts
C. Alarm relay contacts
D. Interconnect cable contacts

Reference Manual 21

Install

Wiring Connector Locations (Control Board)Figure 2-9:

A. Plant status in
B. Analog out
C. Receiver cable in
D. Serial data input

Procedure

1. Install the receiver cable in the center rear cable port of the control unit enclosure.
Provide adequate free wire length for making connections to the control board
terminals 16 through 22. Tighten the cable gland nut.

2. Connect the receiver cable wires to the control board terminals 16 through 22
according to the wiring diagram, Figure 2-7.

Do not connect the receiver cable shield wire at the control unit.

22 Rosemount CCO 5500

Install

3. Install the source cable in the right front cable port of the control unit enclosure.
Provide adequate free wire length for making connections to the control board
terminals 8 through 12. Tighten the cable gland nut.

4. Connect the source cable wires to the control board terminals 8 through 12
according to the wiring diagram, Figure 2-7.

Do not connect the source cable shield wire at the control unit.

5. Install one end of the power supply to control unit interconnect cable in the center
front cable port of the control unit enclosure. Provide adequate free wire length for
making connections to the control board terminals 1 through 7. Tighten the cable
gland nut.

6. Connect the cable wires to the control board terminals 1 through 7 according to the
wiring diagram, Figure 2-7.

Do not connect the cable shield wire at the control unit.

7. Install the opposite end of the power supply to control unit interconnect cable in
one of the right hand cable ports of the power supply unit enclosure. Provide
adequate free wire length for making connections to the power supply board
terminals 1 through 7. Tighten the cable gland nut.

8. Connect the cable wires to the power supply board terminals 1 through 7 according
to the wiring diagram, Figure 2-7.

Do not connect the cable shield wire at the power supply unit.

9. Install the 110/220 Vac power cable in one of the left hand cable ports of the power
supply unit enclosure. Provide adequate free wire length for making connections to
the power supply board terminals: L, N, and E. Tighten the cable gland nut.

10. Connect the cable wires to the power supply board terminals L, N, and E according
to the wiring diagram, Figure 2-7.

Do not connect the power cable to the facility power source at this time.

11. Verify that the power switch is in the correct position.

The voltage position selected must match the voltage supplied to the Rosemount
CCO 5500 Analyzer at your facility.

12. Connect two separate earth ground leads to the ground screws located on the left
hand side of the power supply unit and control unit enclosures.

NOTICE

To maintain proper earth grounding, ensure a positive connection exists between the
enclosures and the earth. The connecting ground wires must be 14 AWG minimum.

™

Reference Manual 23

Install

24 Rosemount CCO 5500

3 Configuration and startup

3.1 Introduction

You may need two hours or more to configure the instrument, and you need to complete
the following tasks:

• Power up

• Alignment*

• Gain adjustment*

• Set operating parameters

• Calibration*

Note

*Perform these operations when a clean stack condition exists.

Configuration and startup

3.2 Safety considerations

The power supply unit supplies power to the analyzer system. Before removing any
equipment covers, lock out and tag out power to the supply unit.

WARNING!

ELECTRIC SHOCK
Disconnect and lock out power before connecting power to the analyzer.

3.3

Power up the Rosemount™ CCO 5500 Analyzer

Use the following procedure to power up the analyzer.

1. Make sure that the voltage and frequency of the AC power supply match the
required power specifications.

2. With the AC power supply locked out and tagged off, unscrew and remove the
power supply unit cover.

3. Select the correct power supply voltage using the AC power selector switch shown
in Figure 3-1.

Reference Manual 25

Configuration and startup

Power SupplyFigure 3-1:

A. AC power selector switch
B. Rail indication LED

3.4

4. Power up the Rosemount CCO 5500 Analyzer and verify that the power supply rail
indication LED (Figure 3-1) lights up.

5. Install and fasten the power supply unit cover.

6. Check that the LCD display is functioning at the control unit.

While the source unit is warming up, the LCD display shows WAITING FOR REFERENCE.
When the source unit reaches an adequate temperature for the reference to be detected,

the LCD display shows the message STABILIZING REF, along with the frequency and
mark/space ratio. See Section 4.9 for further details.

The reference frequency takes some time to stabilize (about five minutes from cold
startup). When the reference frequency is within tolerance for 10 consecutive
measurement cycles, the instrument automatically changes to the OPERATING mode. This
is Mode 1 and is indicated by a number 1 appearing in the top left corner of the LCD

display. The display shows a reading in ppm; this is not an accurate reading until all
configuration and startup procedures are completed.

Before conducting the alignment procedure, allow 30 minutes for the source temperature
to become stable.

Alignment

For the instrument to operate properly, the source and receiver units must be aligned.
Rosemount™ has built in a degree of optical redundancy; normal duct movements do not
affect the operation of the instrument. Read and understand this entire procedure before
starting the alignment.

26 Rosemount CCO 5500

Configuration and startup

1. See Figure 2-5. Unscrew the four screws that secure the receiver to the air purge.
Remove and place the receiver in a safe location.

2. Go to the source unit location. To align the source, turn the adjusting nuts
(Figure 3-2). Use opposing adjusting nuts to align the source unit in one plane, then
the other.

Note

You can achieve receiver alignment by monitoring the output of the detector directly. Use a
voltmeter set to AC volts (10 V max.) to measure across test points S0V and S2 for D3, and
S0V and S1 for D1 on the receiver control board (Figure 3-3). This alignment method is useful
when the receiver is not located near the control unit.

Alignment FeaturesFigure 3-2:

A. Adjusting nuts
B. Locking nuts
C. Air purge
D. Rear flange
E. Front flange

Reference Manual 27

Configuration and startup

Receiver Test PointsFigure 3-3:

A. S1 white
B. S2 blue
C. S0V green
D. Voltage indication LEDs

3. Adjust the alignment until the bright red disc of the source is located centrally in the
field of view when viewed from the receiver air purge. When the source unit is
aligned, tighten the locking nuts.

4. Install and tighten the receiver on its air purge using the four screws removed in

Step 1.

5. At the control unit keypad, press MODE four times to select SET UP mode (Mode 5).
When 5 (SET UP) is displayed on the LCD, press ENTER to access the SET UP

mode.

Note

The analyzer uses a security code to prevent unauthorized alteration of settings. The default
code set at the factory is 0000.

The keypad cursor flashes over the first digit of the security code.

28 Rosemount CCO 5500

Configuration and startup

6. Use the arrow keys to enter the desired value for this digit. Press ENTER to select the
displayed value; the cursor moves to the second digit. Select the value for the
second digit and press ENTER. Continue this process for each digit of the security
code.

When the fourth digit is correctly entered, the processor enters Mode 5.

7. When in Mode 5, select Calibrate using the keypad arrow keys; press ENTER to access
the Calibrate menu.

8. Use the arrow keys to select SET DETECTORS; press ENTER.

The display shows the D1 and D2 detector levels.

CAUTION!

If the analyzer is not in SET UP mode, the gas cell at the source unit periodically
interrupts the IR beam and make alignment difficult.

9. Adjust the receiver alignment, using the adjusting nuts, Figure 3-2. Adjust in one
plane, then in the other.

As a rule, the D2 detector level is affected to a greater extent by adjustment in one
particular plane. The D1 detector level is affected more by adjustment in the other
plane.

10. Make sure the maximum possible values of both D1 and D2 are reached. After you
achieve alignment, tighten the locking nuts.

Note

The alignment of the receiver unit is important. Make sure to obtain the maximum values of
D1 and D2.

11. If the displayed detector level is below 5000, increase the gain at the control unit to
between 12000 and 14000.. If the detector level is above 15000, reduce the gain to
between 12000 and 14000.

Refer to Section 3.5 for details.

12. To fine tune the alignment, repeat adjustments of Step 9 at the source unit. Again,
make sure the values of D1 and D2 are appropriate. Lock the source unit in place
when the maximum values are achieved.

13. When you have properly completed the alignment, there is rarely any need for
further alignment adjustments.

3.5

Reference Manual 29

Detector levels

The gain of the detector signals is set in two locations:

1. In the receiver, two potentiometers set the gain. Refer to Section 3.5.1.

Configuration and startup

2. In the control unit trim, potentiometers adjust the level of the D1 and D2 signals
before they enter the microprocessor. Refer to Section 3.5.1.

It is essential that you properly conduct the alignment procedure and obtain a maximum
detector signal before attempting to optimize the detector levels.

3.5.1 Receiver gain adjustment

To give an optimum signal-to-noise ratio, the detector levels must be maximized. For the
best signal-to-noise ratio, you must set the gain of the detector signals in the receiver to a
maximum without saturating. Rosemount™ sets the gains at a path length of 6.5 f.t (2 m).
If the path length is above 13 ft (4 m) or below 5 ft (1.5 m), you may need to adjust to
optimize the detector levels.

1. Enter Mode 5 → Calibrate → Set Detectors and display the value of D2/D1.

2. Loosen the receiver cable gland so the receiver cable can slip when you remove the
window plate.

3. Pull the window plate (Figure 3-4) from the receiver to access the detectors.

Receiver Trim PotsFigure 3-4:

A. Trim pot for end detector D1
B. Trim pot for side detector D2

4. Trim potentiometer(s) set the gain.

An AC voltmeter measures the gain levels.

5. Connect the voltmeter to the test points on the control unit (18/20 for D1 and
19/20 for D2). Increase the gain using the trim pot at the end detector D2 until the
voltage is between 1 - 4 Vac.

30 Rosemount CCO 5500

6. Repeat Step 5 for the side detector D1 measuring across the test points.

7. When the detector levels are satisfactory, replace the cover.

Note

If the duct is operating and a high opacity may be in the path, reduce the set voltages to 2 V
rms maximum. This should prevent saturation should the opacity level drop off.

3.5.2 Control unit gain adjustment

After you have optimized the detector level(s) at the receiver, optimize the levels within
the microprocessor. Make the adjustment with two trim potentiometers in the control
unit.

1. Set the gain to a minimum by turning the D2 detector trim pot (Figure 3-5) fully
clockwise.

D2 is a 20-turn potentiometer.

Configuration and startup

Reference Manual 31

Configuration and startup

Gain Adjust PotentiometersFigure 3-5:

A. Trim pot
B. Test point
C. LED
D. D2 trim pot
E. D1 trim pot
F. Plant
G. Analog
H. Receiver
I. Serial data

2. Enter Mode 5 → Set Detectors and display the values of D2 and D1. Turn the trim pot
counterclockwise until the D2 level is between 12,000 and 15,000. Allow time
between adjustments for the readings to settle.

Note

If the duct is operating and the opacity levels are high, reduce the D2 level to about 8,500.
This should prevent saturation should the opacity level drop off.

32 Rosemount CCO 5500

3. To ensure that the detector signal is not saturating, observe the saturation count
signal displayed next to the detector levels. If a SAT # of more than 0 is displayed,
turn the trim pot slightly to reduce the gain. Reduce the gain until a SAT # of 0 is
displayed.

4. If saturation is indicated with the trim pot turned fully clockwise, reduce the gain in
the receiver and repeat the procedure.

5. Repeat Step 1 through Step 3 for the D1 level using the D1 trim pot.

Note

Rosemount™ has designed the circuits so that wherever saturation occurs (receiver or control
unit), the microprocessor always detects it. If the displayed detector levels cannot be set to
within this band or saturation cannot be avoided, optimize the detector levels ar the receiver.
Refer to Section 3.5.1.

3.6 Source adjustments

Two trim potentiometers within the source unit allow adjustments to be made to the
intensity of the source and to the frequency of the chopper motor. Rosemount™ sets these
at the factory, and they rarely need adjustment. Rosemount recommends that you consult
the company before making any adjustments within the source unit.

Configuration and startup

3.6.1

CAUTION!

DECREASED SOURCE LIFE

Increasing source intensity may severely reduce the source life.

Source intensity

Complete the following steps to adjust the source intensity in the analyzer.

1. Loosen and slide the source unit cable gland so the cable can slip when the rear
cover plate is removed.

2. Unscrew and remove the rear cover plate.

3. A trim pot (Figure 3-6) allows adjustment to the intensity of the source. Turn the trim
pot clockwise to increase the source intensity.

Reference Manual 33

Configuration and startup

Source Intensity Trim PotFigure 3-6:

A. Trim pot

3.6.2 Chopper frequency

Complete the following steps to adjust the analyzer's chopper frequency.

1. Unscrew and remove the source from the air purge.

2. Unscrew and pull the window plate from the front of the source unit.

See Figure 3-7. A trim pot (VR1) allows you to adjust the frequency of the chopper
motor.

34 Rosemount CCO 5500

Configuration and startup

Chopper Frequency Trim PotFigure 3-7:

3.7

A. Trim pot VR1

3. To increase the chopper frequency, turn the trim pot counterclockwise.

Set up mode

To prevent any unauthorized changes, you must enter a four digit security code to enter
the set up mode.
You must set operating parameters in the instrument for proper analyzer operation. All
operating parametrs are set within the control unit using the SET UP mode. In the SET UP
mode, parameters are held in non-volatile memory and retained in the event of a power
loss.

Even if the measured data is not going to be normalized, you must set the normalizing
parameters to ensure proper analyzer operation.

Note

When you select SET UP mode, the instrument suspends motor operations, and the Data Valid LED
goes dim. If no key is pressed within five seconds after selecting SET UP mode, the instrument control
reverts to OPERATING mode.

Chapter 4 lists all parameters in full. Basic details are given here for configuration purposes.

To aid configuration and to record any subsequent changes to the operating parameters,
Rosemount recommends completing to provide a record of the instrument setup.

Reference Manual 35

Configuration and startup

Procedure

1. Press MODE unil the number 5 is displayed in the top left corner.

After you correctly enter the security code, there are six submodes of operation
from which the set up parameters may be changed. These six submodes are:

a. Set Averages: The four averaging stack times (seconds, minutes, hours, and

days) may be set as required.

b. Configure O/P - Analog output setup: Origin, units, span, rolling average, and

fault condition.

c. Parameters: The following are set from this mode: security code, identity

number, path length, alarm level, cal factor, and plant status.

d. Normalization: You may set up all normalization parameters from this mode.

e. Reset Average: Select this submode to reset the four averaging stacks.

f. Calibrate: Set the outputs of the detectors and the basic calibration for the

instrument.

2. Use the arrow keys to toggle between these six options and press ENTER when the
desired option is displayed.

3.7.1 Enter security code

Complete the following steps to enter the security code.

1. Once the display is as shown here, press ENTER to gain access to SET UP mode.

The cursor flashes over the first digit of the security code number.

2. Select the required first digit with the arrow keys and press ENTER.

3. Repeat this procedure for the remaining three numbers.

If the code is correct after you press ENTER on the last digit, the sequence is
continued. If it is not correct, the instrument returns to OPERATING mode. Refer to

Section 3.7.4 for further details.

Note

Rosemount™ sets the code number to 0000 at the factory; you should change it in SET UP
mode.

3.7.2

Set averages

The instrument calculates four separate averages. These are defined in units of seconds,
minutes, hours, and days. You can use any of the four averaging stacks to provide the
instrument's analog output. You can set each averaging time within predefined limits.

36 Rosemount CCO 5500

Configuration and startup

1. Press ENTER when this display is shown.

The display now shows one of the averages.

2. Use the arrow keys to select the average time that you need to change and press
ENTER to change it.

You can now change the value using the arrow keys and confirm it by pressing
ENTER.

3. Set the seconds averaging stack to the required value.

This is limited to within 10 to 60 seconds in 10-second intervals.

4. Set the minutes averaging stack to the required value.

3.7.3

This is limited to within 1 to 60 minutes in 1-minute intervals.

5. Set the hours averaging stack to the required value.

This is limited to within 1 to 24 hours in 1-hour intervals.

6. Set the days averaging stack to the required value.

This is limited to within 1 to 30 days in 1-day intervals.

Configure O/P

You can set up the analog loop output from this mode.

1. Press ENTER while this display is shown to access it.

Reference Manual 37

Configuration and startup

2. Press the arrow keys to step through the available options.

3. Press ENTER to access and change the displayed parameters of each of the six
available options listed below:

a. Output

b. Averages

c. Units

d. Output Span

e. Fault Condition

f. Set mA Output

Output

You can set an origin of 0 or 4 mA for the current loop output. The arrow keys toggle
between these two options. Press ENTER to enter the new value.

Average

You may use any of the four averaging stacks (seconds, minutes, hours, and days) for the
analog output. You can select them with the arrow keys and enter them with the ENTER
key.

Units

The analog output can represent the gas concentration in units of mg/m3, mg/Nm3, or
vpm. The arrow keys toggle between these three options. Press ENTER to enter the new
value.

Output Span

Select the required span using the arrow keys for each digit. Press ENTER to enter the value
of each digit. The units are displayed in vpm, mg/m3, or mg/Nm3, depending on what has
been selected beforehand.

38 Rosemount CCO 5500

Configuration and startup

Note

Once you select Output Span, the current value is displayed for one second. The first digit of the
display then defaults to zero; thus you must re-enter the span value for the unit to function correctly.

Fault condition

If a fault condition occurs, you may set the current output of the instrument to one of the
following options:

Procedure

1. Set the output at 0 mA - ZERO.

2. Adjust the output to the calculated gas concentration even though a fault condition
exists - MEAS.

3. Hold the last selected gas concentration - HOLD.

4. Set the output to full scale (20 mA) - F.S.

Press the arrow keys to select one of these options; when the desired output is displayed,
press ENTER to confirm.

Set mA output

Note

This is set at the factory and should not be altered without due consideration.

From this option, the current levels of the analog output are set up. Press ENTER to select
it, and the instrument prompts you to set the current levels at 0 and 20 mA.

When this is displayed, set the current output to 0 mA as measured with a calibrated
current meter across the analog ouput loop terminals; do not connect anything else to
these terminals when setting up the output.

Use the two arrow keys to adjust the value; the UP arrow takes the current output up, and
the DOWN arrow takes it down. Press ENTER when the correct output is displayed on the
ammeter.

Reference Manual 39

Configuration and startup

Note

Zero mA should be set up no matter what has been selected as the base of the current output. This is
factory set.

In a similar manner to the above, set the current output level to 20 mA.

3.7.4 Parameters

Complete the following steps to set the parameters.

1. With this option displayed, press ENTER to access the list of six available options.

The arrow keys cycle through these options.

2. When the option you need to change is displayed, press ENTER.

3. When you have made all required changes, select EXIT and press ENTER.

The six available options are:

a. Security Number

b. Identity Number

c. Path Length

d. Alarm

e. Cal. Factor

f. Plant Status Input

Security Number

To prevent any unauthorized tampering with the setup information, it is important to
change the security code from the factory setting.

Select each digit with ENTER and change it with the arrow keys.

Note

It is important to make note of this number; otherwise, it will not be possible to change the
instrument set up.

40 Rosemount CCO 5500

Configuration and startup

Identity Number

If you are using the system as part of an integral monitoring system and are using the serial
input and outputs, the central processor requires a Device Identity to identify each
instrument. This number must be unique for each equipment item and can be set from 1
to 30 as required.

Path Length

Note

Once you select path length, the instrument displays the current value for one second. The first value
of the display then defaults to zero; therefore, you must re-enter the value to calculate the gas
concentrations correctly.

The transmissivity of any gas depends both on the concentration and on the path length
through which the radiation is transmitted. Similarly, the output of the Rosemount™ CCO
5500 Analyzer gas monitor also depends on the path length of the flue gas through which
the radiation is transmitted.

Refer to Section 2.4.1.

The Rosemount CCO 5500 Analyzer is sensitive to the product of concentration and path
length. In order to obtain a true value of concentration of gas, you must input the correct
path length into the processor. The processor then uses the value to produce a final value
of gas concentration.

Note

The path length entered must represent the length of the actual gas pass, not the flange to flange
dimension between the source and receiver.

Alarm

A contact output is available to warn of a high gas concentration. You may trigger the
contact output from any of the four averaging stacks. Select the source with the arrow key
and enter it with ENTER.

Reference Manual 41

Configuration and startup

Select the units for the alarm; these may be different than the units selected for the analog
output.

After you select the source, the instrument requires a level that will trigger the output. Set
the desired level with the arrow keys.

Cal Factor

Note

First, record the original Cal Factor before entering this mode as displayed in Mode 4 → Calibration
Data. The Cal Factor is lost when the menu option is entered.

During the calibration routine, the instrument calculates a Cal Factor which sets the basic
calibration of the instrument. You may change this value from this mode.

Note

Since this value controls the calibration of the instrument, only change if necessary.

Plant Status Input

Use this to determine whether the plant is operating under correct conditions.

There is a choice of three controls for plant status: Logic Input, Serial Input, and Multiple. You
can only use one to control plant status at any one time.

• Logic Input

If the PS1 and PS2 terminals are linked in the control unit, the logic contact is made,
and the plant status is OFF. You may link these terminals manually during a plant
shut down, or you may wire them to a switch/contact outside the unit (e.g., a value
that opens and closes the duct). Press ENTER to select this option when the Plant
Status → Serial Input option is displayed.

• Serial input

42 Rosemount CCO 5500

Configuration and startup

If you select this option, the criteria controlling plant status are transmitted via the
serial data link. Press ENTER when the Plant Status I/P → Serial Input option is
displayed to select this option.

• Multiple

Four options are available here. Press ENTER when the Plant Status I/P → Multiple
option is displayed, and the first option Temperature is displayed. Use the arrow keys
to toggle YES or NO. NO means that the temperature threshold is not used to
determine plant status. If you select YES, the display enters the display below.
Configure the instrument for temperature threshold. Press ENTER when it is
correctly configured, and the display moves to the next option Oxygen. After you set
the last option, the Logic Input display returns to the PARAMETERS → Plant Status I/P
option. Use the DOWN arrow to scroll down to EXIT and press ENTER. The plant
status is now full configured.

Plant status is only OFF if all options selected are registering plant status OFF. If any
one of them is not fulfilling plant status OFF conditions, then the instrument
registers plant status ON.

- Temperature

A value is set here for the temperature threshold. While the temperature (taken
from the normalizing temperature) is above the threshold value, plant status is
ON. If the temperature drops below the threshold, plant status is OFF, and only
the seconds averaging stack updates.

- Oxygen

Oxygen is set and used in a similar manner to the temperature threshold.
However, if the normalizing oxygen level rises above the threshold, plant status
is OFF. For plant status ON, the oxygen level must be below the threshold.

- Water Vapor

This is set and used in a similar manner to the temperature threshold. If the
normalizing water vapor level falls below the threshold, plant status is OFF. For
plant status ON, the water vapor level must be above the threshold.

- Logic Input

Select YES or NO and press ENTER. For plant status to be ON, the logic input (PS1
and PS2) must be open circuit; for plant status to be OFF, the logic input must be
closed circuit. After you configure this option, the menu exits to the Multiple
option. Use the DOWN arrow to select EXIT and press ENTER.

3.7.5

Reference Manual 43

Normalization

Complete the following steps to set the Normalization parameters.

1. Press ENTER to access one of the four normalizing parameters listed below.

Configuration and startup

2. Use the arrow keys to cycle through the four options and press ENTER once the
desired option is selected.

a. Temperature

b. Oxygen

c. Pressure

d. Water Vapor

Once selected, each of the above normalizing parameters have the same suboptions: Set
Standard Levels and Set Values. Under Set Values, are three more suboptions that determine
how the instrument reads the data: Analog Input, Serial Input, and Keypad Input.

Set Standard Levels

Each normalizing parameter normalizes the measured gas concentration to standard
conditions of temperature, oxygen, pressure, and water vapor. Set these levels within this
option. Use the arrow keys to change each displayed normalizing standard value.

Temperature

Always use an analog input for temperature correction; this ensures that the flue gas
temperature is being measured continuously and accurately. Connect the analog output
of the temperatue transducer into the Rosemount™ analyzer and select the analog input
option. This value is used to normalize the gas concentration measurement and to correct
for the effects of temperature on the IR absorption spectrum.

If you use the Keypad Input, and the gas temperature is higher than 572 ° F (300 °C), the
compensation algorithm becomes less precise, and instrument accuracy deteriorates
accordingly. Rosemount does not recommend this.

Note

If normalization is not required, the instrument must hold the temperature of the gas in the duct
using the Analog Input option.

Press ENTER with the Temperature option selected to access Set Standard Levels and Set Values.
Use the arrow keys to toggle between these options and Exit.

Set Values

You can bring the normalizing data into the instrument in one of three ways:

• Analog Input

44 Rosemount CCO 5500

Configuration and startup

This uses the 4-20 mA inputs within the processor to receive the measured
transducer data. The values at 4 mA and 20 mA will be requested should this option
be selected.

• Serial Input

If you use an input unit, all normalizing data can be transmitted via the serial data
line.

• You can enter a fixed value via the keypad. This is suitable where the value is stable

to about ±5%.

With an integrated system, set the lead analyzer's normalizing parameters to the 4-20 mA
inputs. Then set all the other analyzers to serial, and the normalization parameters are
transmitted down the serial data highway.

Oxygen

To correct the data to standard levels of oxygen, you must enter an estimate of the oxygen
at the point of measurement. If the oxygen level is being continuously measured, connect
the analog output of the oxygen analyzer into the Rosemount™ CCO 5500 Analyzer and
select Analog Input. You must define this input as either WET or DRY depending on how the
measurement is made. After you define the wet or dry, you need to define the Analog Input
values; set the 4 mA and 20 mA values. If the oxgyen level is relatively constant through all
firing conditions, you may use a fixed keypad input.

With an integrated system, you can take the oxygen data to the instrument via the serial
data line.

Note

If normalization is not required, you must set the normalizing parameters for oxygen in the
instrument.

Pressure

To correct the data to a standard pressure, normally 14.7 psi (101 kPa), you must
determine the pressure at the point of measurement. If the flue pressure is relatively
constant through all firing conditions, then you may use a fixed keypad input. If the
pressure, is not constant, measure it and bring it into the instrument via the 4-20 mA
analog input within the processor.

Reference Manual 45

Configuration and startup

Note

If normalization is not required, set the normalizing parameters for pressure in the instrument to

14.7 psi (101 kPa)(Standard Level and Keypad Input).

With an integrated system, you can take the pressure data to the instrument via the serial
data line.

Water Vapor

An across the duct monitor measures the gas concentration under wet conditions. Unlike a
sampling system, the gas has not been preconditioned in any way before you make a
measurement.

When the water vapor is at a relatively fixed level, set the standard level to DRY to
normalize it to dry conditions. Use a fixed value in the keypad option representing the
expected water vapor produced for the fuel type. If the measurement is not to be
normalized for water vapor, set the standard level to WET.

With an integrated system, you can take the water vapor data to the instrument via the
serial data line.

3.7.6 Reset averages

Note

Resetting averages causes the rolling average data to be cleared from memory.

You can reset the average values that are currently held in the four averaging stacks using
this option; this ereases the current average that is held in all of the averaging stacks.
Select this option by pressing ENTER and using the arrow keys. The instrument requests
confirmation before the averages are reset.

Note

If you select this option, all the data in the averaging stacks is reset, and the data for as much as 30
days is lost.

3.7.7

Calibrate

From this option, you may display the two detector levels and conduct a basic calibration.
While in this mode, the gas cell is not moved; this gives an immediate response for setting
up the detector levels. A Cal Factor that is calculated during a calibration routine sets the
basic calibration of the instrument. Press ENTER while this is displayed to see the following
options:

1. Set Detectors

46 Rosemount CCO 5500

Configuration and startup

2. Span Adjust

3. Calibrate

Set detectors

You can display both the D1 and D2 levels; you can also display saturation counts. To give
an immediate response to any alterations that are required, the filters and gas cells are not
moved during this operation.

Refer to Section 3.5 for a discussion of the detector level and saturation count.

Span adjust

Note

Rosemount™ initially sets the span factor at the factory; do not adjust it unless the instrument
sensitivity is suspected. In any case, Rosemount recommends that you record the orginal value
before making adjustments.

You can adjust instrument sensitivity if a known concentration of gas exists between the
source and receiver units and instrument sensitivity is supsected. If a problem arises,
consult Rosemount.

You may need to adjust the span factor if you have fitted new gas cells or filters.

Calibrate

Re-enter the Mode 5 CALIBRATE menu and proceed to the Calibrate option.

You can calculate the basic calibration of the instrument from this routine. It is preferable
to conduct this operation with the plant shut down to ensure a zero gas concentration
within the duct. If this is not possible, the instrument can calibrate to a known value of the
gas concentration - the calibration target.

Reference Manual 47

Configuration and startup

Set the calibration target either to a known value of the gas concentration or to zero. Then
set the desired number of cycles over which the calibration factor is determined
(Rosemount™ recommends a minimum of 30). Now run the calibration, and the display will
show a countdown during its execution. When the calibration is complete, the new Cal
Factor is displayed for about five seconds, and the instrument exits the calibration routine.

Note

You must run the calibration routine during commissioning; otherwise, the instrument will not be
able to calculate the true level of gas within the duct.

Do not run the calibration routine unless reasonable conditions exist in the duct. If it is not
the initial calibration, record the Cal Factor from the Parameters option before running the
calibration.

To aid configuration and to record any subsequent changes to the operating parameters,

Table 3-1 lists all of the options available and can be used as a record of the operating

parameters.

Instrument SettingsTable 3-1:

Parameter Config

Averages

Seconds

Minutes

Hours

Days

Output

0 or 4 mA base

Units

Average

48 Rosemount CCO 5500

Instrument Settings (continued)Table 3-1:

Parameter Config

Fault condition

Parameters

Path length

Alarm source

Alarm units

Alarm levels

Normalization

Temperature

Standard level °F (°C)

I/P °F (°C) @ 4 mA

I/P °F(°C) at 20 mA

Keypad input °C (not ideal)

Serial input

Configuration and startup

Oxygen

Standard level %

Wet or dry gas

I/P % @ 4 mA

I/P % @ 20 mA

Keypad input %

Serial input

Pressure

Standard level psi (kPa)

I/P psi (kPa) @ 4 mA

I/P psi (kPa) @ 20 mA

Keypad input

Serial input

Water vapor

Standard level (wet %/dry

Keypad input %

Measured value

After the instrument calibrates, it calculates a cal factor; this determines the calibration of
the instrument. The instrument displays the cal factor for a few seconds after calibrating,
and you can also interrogate the cal factor from Mode 4 (DIAGNOSTIC mode). Enter the cal
factor into the table below as a record of instrument operation.

Reference Manual 49

Configuration and startup

Note

Rosemount™ obtained factory settings under the following conditions:

• 2 m path length

• Clean conditions

Calibration DataTable 3-2:

Detector outputs Factory Config

D2

D1

E1

E2

Calibration data

Cal factor

Span factor

Output calibration

Set zero

Set span

3.8 Current output calibration

Now set up the current output using a calibrated multimeter set to DC current, 20 mA
max. Conduct this procedure as follows:

Note

Rosemount™ sets the current output at the factory; do not alter it.

Procedure

1. Connect the multimeter to the output terminals within the control unit terminals
+mA and -mA.

2. Enter Mode 5 → Configure Output → Fault Condition → Set Zero and adjust the level
using the arrow keys until 0 mA is recorded. Record the value in brackets on the

display in Table 3-2.

3. Enter Mode 5 → Configure Output → Fault Condition → Set Span and adjust the level
using the arrow keys until 20 mA is recorded. Record the value in brackets on the

display in Table 3-2.

50 Rosemount CCO 5500

4 Operation

4.1 Introduction

After you configure the Rosemount™ CCO 5500, it measures the gas levels between the
source and receiver and produces an output proportional to the gas levels. An integral 32­character LCD display also shows the calculated levels.

The Rosemount CCO 5500 Analyzer allows you to interrogate the microprocessor to
observe the system parameters and to change them if required.

The Rosemount CCO 5500 uses a menu-based program; you can gain access to it by the
key panel mounted on the lid of the control unit (Figure 4-1).

Control Unit KeypadFigure 4-1:

Operation

A. 32-character liquid crystal display
B. Keypad
C. Data valid and alarm LEDs

4.1.1

Reference Manual 51

Measurement

Once the analyzer has completed configuration, it measures the absorption of IR radiation
and calculates a parameter Y.

Operation

Refer to Section A.7. The analyzer uses this value to produce a final concentration of gas
that can be normalized to standard conditions and averaged over a time ranging from 10
seconds to 30 days.

The instrument computes four averages, any of which can be used to drive the analog
output or displayed on the integral 32-character LCD.

4.1.2 Calibration

During the configuration procedure, the analyzer conducts a calibration that sets the
system gains to produce a zero or known gas level. Once the analyzer has conducted the
routine, precision filters, which do not change, fix the calibration of the instrument .

4.2 Startup and operation

Power up the system and wait for 30 minutes. This allows time for the infrared source to
heat up. Once the receiver is detecting a signal, you will see a reading on the control unit
display. This should be in normal OPERATING mode, Mode 1 (shown by a number 1 at the

top left corner of the LCD); the display also shows a reading in vpm, mg/m3, or Nmg/m3. If
this appears, the system is functioning properly.

4.3 Modes of operation

The instrument has six modes of operation identified by a number in the top left corner of
the display.

Mode 1: Operating Mode

Displays average gas concentration.

Mode 2: Parameters

Displays operating parameters.

Mode 3: Normalization

Displays normalization data.

Mode 4: Diagnostics

Investigates instrument operation. The instrument continually checks itself; if a
complicaiton exists, the instrument automatically selects this mode and displays the fault
on the display.

Mode 5: Set up Mode

Sets operating parameters. You must enter the opening parameters for the instrument to
function correctly. You can only access this mode using a security code.

52 Rosemount CCO 5500

Mode 6: Check Cell Mode

Used to verify the instrument's operation and calibration.

Note

The outputs of the instrument are unaffected by key operation in all modes except the Set up mode.

4.4 Keypad operation

You can access each mode sequentially by each push of the MODE key.

Figure 4-1 illustrates the display and keys of the control unit. After you select a mode, use

the arrow keys to select the various options within these modes. Use the ENTER key to
input the displayed value and step the cursor to the next option where applicable.

1. MODE key: Press the MODE key to either take the instrument to the next mode of
operation or back to the OPERATING mode if pressed from within a mode.

2. Arrow keys: Press the arrow keys to do one of two things, depending on the position
in the program:

• It increases ↑ or decreases ↓ the displayed value. If you hold down the key, it

scrolls quickly to the desired value.

• It steps through the available options within a mode or submode.

3. ENTER key: Press the ENTER key to do one of two things, depending on the position
in the program:

• It inputs the displayed parameter value.

• It selects the displayed mode or option from within a mode or submode.

Operation

Note

Allow time for the instrument to respond to a key instruction; otherwise, it may record a double key
entry.

4.5

Reference Manual 53

Menu tree

Figure 4-2 shows the arrangement of the Rosemount™ CCO 5500 Analyzer menu tree.

Operating mode

Parameters

Normalization

Diagnostics

Set up mode

vpm, mg/m

3

,

mg/Nm

3

,
Measure,
Normalized,
Sec, Min, Hour,
Day

Identification

Parameters

Averages

Output alarm
Plant status
Exit

Analyzer type
EPROM program ID
Identity number

Path length
Span factor
O/P fault

Sec, Min, Hour, Day

On, Off
Plant St. I/P

Temperature threshold
Oxygen threshold
Water vapor threshold

Temperature
Oxygen
Pressure
Water vapor
Exit

Detector outputs
Mod. Frequency
Yval & CO ppm
Calibration data
Fault condition
Exit

Security code

Set averages

Configure O/P

0000 to 9999

Seconds

Minutes

Hours

Days

Exit

10 to 60 s @ 10 s intervals

01 to 60 m @ 01 m intervals

01 to 24 h @ 01 h intervals

01 to 30 d @ 01 d intervals

Output

Average

Units

Set span

Fault condition

Set mA O/P

Exit

(0 or 4) to 20

Sec, Min, Hour, Day

vpm, mg/m

3

, mg/Nm

3

0 to 9999 span

Zero, Mea, Hold, F.S.

Set zero
Set span

Operation

Rosemount CCO 5500 Analyzer Menu TreeFigure 4-2:

54 Rosemount CCO 5500

Set up mode

Check cell
mode

Parameters

Normalization

Reset averages

Calibrate

Security

Identity

Path length

Alarm

Cal. factor

Plant St. I/P

Exit

4 digit code

01 to 30

Gas path length in mm

Source

Units
Alarm level (0 to 9999)

0 to 9999

Logic
Serial
Multiple
Exit

Sec, Min, Hour, Day

Vpm, mg/m

3

, mg/Nm

3

Temperature

Oxygen

Water vapor

Det. level

Logic

Yes, No

Yes, No

Yes, No

Yes, No

Yes, No

Temperature

Oxygen

Pressure

Water vapor

Exit

Set std. levels
Set values
Exit

Analog input
Serial input
Keypad input
Exit

Set std. levels
Set values
Exit

Set std. levels
Set values
Exit

Set std. levels
Set values
Exit

Analog input
Serial input
Keypad input
Exit

Analog input
Serial input
Keypad input
Exit

Serial input
Keypad input
Exit

Yes, No

Set detectors
Span adjust
Calibrate
Exit

Yes, No

Operation

4.6 Operating mode

From this mode of operation, you may alter the averaging time of the displayed gas
concentration to one of the other averaging stacks and observe the measured/normalized
gas measurements. When in this mode, the display appears similar to that shown below. If
the display is not similar to this, press MODE until number 1 appears at the top left corner

of the display.

Reference Manual 55

Operation

To change the data displayed, press ENTER, and a flashing cursor appears at the beginning
of the concentration units, i.e., vpm or mg/Nm3. The arrow keys now change the

highlighted parameter. Each push of ENTER selects another of the parameters in the
following order:

1. Concentration units: vpm, mg/m3 (or mg/Nm3).

2. Measured or normalized display.

3. Averaging time: seconds, minutes, hours, or days.

Press ENTER when the cursor is flashing on the averaging time, and the cursor disappears
from the display. You may press ENTER again if required to bring the cursor back onto the
display.

4.7 Parameters

4.7.1

4.7.2

In this mode, you can examine the parameters set within the SET UP mode, but you cannot
change them. Press MODE until the number 2 appears in the top left corner of the display;

then press ENTER. Use the arrow keys to scroll through the available options; press ENTER
to display one of the selected options below.

1. Identification

2. Parameters

3. Averages

4. Output Alarm

5. Plant Status

Press ENTER again to exit from each option.

Refer to Section 4.10 for further details of the display information and how to change the
held parameters.

Identification

You can display the analyzer type, identity number, and EPROM program ID from this
option. Use the arrow keys to scroll between these options.

Parameters

You can display the following parameters from this option; select them using the arrow
keys.

1. Path Length: The path length currently used to calculate the gas calculation.

56 Rosemount CCO 5500

2. Span Factor: You can adjust the sensitivity of the instrument from the SET UP mode
→ CALIBRATE option. Rosemount™ initially set the span factor at the factory using
known gas concentrations.

3. O/P (Output) Fault: Should a fault condition occur, you can set the analog input from
one of four options.

4.7.3 Averages

Select this option to display the times set for each of the four averaging stacks: seconds,
minutes, hours, and days.

4.7.4 Output

You can display the base, span, and averaging of the analog output from this option.

4.7.5 Alarm

A changeover relay contact output is available to indicate a high gas concentration. You
can examine the level at which the output is operated and the averaging stack from which
the gas value is obtained from this display.

Operation

4.7.6 Plant status

When plant status is OFF, the minutes, hours, and days averaging stacks do not update.

Note

When the plant status is OFF, pollutant levels are zero. It is not normally permitted to use plant OFF
zero levels to reduce the recorded mean entitled pollutant levels.

You can use this function to ensure data is only collected when the plant is fully
operational. You can use three options to determine plant status ON or OFF: Logic Input,

Serial Input, and Multiple. Multiple has four options: Temperature threshold, Oxygen threshold, Water
Vapor threshold, and Logic Input. You can view the plant status and its governing factor from

this display.

4.8

Normalization

Complete the following steps to display and/or edit the normalization parameters for the
analyzer.

1. Press MODE until you see the number 3 in the top left corner of the display.

From this mode, you can display the normalization parameters currently used.

2. Press ENTER to enter the routine and use the arrow keys to select which of the
normalizing parameters to display.

Reference Manual 57

Operation

Listed below are the four normalizing parameters accessible through this mode:

a. Temperature

b. Oxygen

c. Pressure

d. Water Vapor

3. When you see the required normalizing parameter, press ENTER to display the
normalization data. Press ENTER again to exit the parameter.

For each of the four normalizing parameters, the display appears similar to that
shown below.

Normalization ExampleFigure 4-3:

A. Selected parameter
B. Units
C. Standard level required (wet or dry for water vapor)
D. Parameter source

• k = keypad input

• a = analog input

• s = serial data input

• m = measured input

4.9

4.9.1

58 Rosemount CCO 5500

Diagnostic mode

You may examine the detector levels, chopper blade frequency, Y parameter, and the fault
condition from this mode. Press MODE until the number 4 appears in the top left corner of

the display and press ENTER to access this mode. Once in Diagnostics, the five suboptions
are as follows:

1. Detector outputs

2. Modulation Frequency

3. Yval and CO ppm

4. Calibration Data

5. Fault Conditions

Detector outputs

This mode displays detector levels from the detector. D1 is the reference level and should
always be less than D2. The level of D2 should be between 10,000 and 20,000.

E1 and E2 are the detector levels with the gas cell within the source unit in the sight path
and will be roughly ½ of the D2 and D1 levels. The analyzer may also display smoothed
detector values; these are noted as d1, d2, e1, and e2.

Sat. # indicates whether the detector signals are saturating within the micro-processor
(this value should always be zero). If it displays a number other than zero, it indicates
saturation, and you should adjust the detector gain. Refer to Section 3.5.

Phase is the time correction applied for the calculation of the detector levels. This will be
between 0.1 and 5.9 milliseconds. The instrument calculates this value, and you may not
adjust it.

4.9.2 Modulation (chopper motor) frequency

The chopper blade should chop the IR radiation at a frequency of about 37 Hz. The
processor measures this frequency and displays it from this option.

Operation

4.9.3

As the chopper blades interrupt the IR beam, they split the radiation into two. Half the
time the blade obscures the beam, and half the time the beam radiates across the duct.
The value of Mark/space should be between 0.9 and 1.1 where:

Mark/space = Time IR beam obscured/Time IR beam clear.

YVals and CO ppm

A parameter Y determines the calculation of the gas concentration; refer to Section A.7.5.

As a check on the program operation, you may view this parameter and the resulting raw
gas calculation here.

The term Yx is the second averaging stack's held value, and the term Y(60) is the 60­second raw value from which all of the other averaging stacks are calculated. These gas
values represent the raw data before averaging for the corresponding Y values. You can
also display the Z values by pressing the arrow keys. The Z values are the adjusted Y values
used to compensate for cross sensitivities in the measurement range.

Reference Manual 59

Operation

4.9.4 Calibration data

You can examine the calibration factors determined during the calibration routine (SCcal)
and the value currently being used (SCwkg) from this display. If the two values are
different, this indicates a change in instrument temperature between the time of
calibration and the current temperature. Press one of the arrow keys to examine the
temperature information.

Temperature has a small effect on the filter/gas cell characteristics compensated for by the
instrument. Temperature measurement is made within the receiver.

4.9.5 Fault condition

To display the current fault condition, press ENTER while this is displayed.

The instrument automatically selects this display mode if a fault condition occurs. The
instrument recognized the following fault conditions:

1. ALL CLEAR: No fault condition.

2. Det. Saturated: The detector level gain within either the receiver or the control unit
is too high for the current duct conditions.

3. Low Det. Level: Detector levels are too low (< 3,000).

4. Mod. Freq.O.R.: Chopper motor frequency is out of range (< 30 Hz or > 45 Hz).

5. Reference Fail.: No reference signal from the source unit.

6. Cal. Fact. O.R.: After the calibration routine, the calculated Set Cal factor is out of
range. Refer to Chapter 6.

Press the arrow key to observe the previous fault condition.

Note

If a fault condition exists, the instrument does not update the minutes, hours, and days averages.
Refer to Section 6.1.1.

60 Rosemount CCO 5500

4.10 Set up mode

You can change all operating parameters (averaging times, output settings, normalization
parameters, path length, calibration, etc.) from this mode. To prevent any unauthorized
changes, you must enter a four digit code before you can enter this mode.

Note

After you select this mode, the instrument suspends its operation and extinguishes the Data Valid
LED. If you don't press a key within five seconds after selecting this mode, the Rosemount™ CCO
5500 Analyzer will revert to the normal OPERATING mode.

Rosemount recommends that you complete Table 4-1 to provide a record of the
instrument setup in order to aid configuration and to record any subsequent changes to
the operating parameters.

Press MODE until the number 5 is displayed in the top left corner. After you have correctly
entered the security code, there are six submodes of operation from which you can change

the setup parameters. These six submodes are listed below:

1. Set Averages: You may set the four averaging stack times (seconds, minutes, hours,
and days) as required.

2. Configure O/P: Analog output setup: origin, units, span, rolling average, and fault
condition.

3. Parameters: You may set the following from this mode: security code, identity
number, path length, alarm level, cal factor, and plant status.

4. Normalization: You may set up all normalization parameters from this mode.

5. Reset Average: Select this submode to reset the four averaging stacks.

6. Calibrate: You can set the outputs of the detectors and the basic calibration of the
instrument.

Operation

Use the arrow keys to toggle between these six options and press ENTER when the desired
option is displayed.

4.10.1

Reference Manual 61

Enter security code

Complete the following steps to enter the security code.

1. Once the display is as shown here, press ENTER to gain access to SET UP mode.

The cursor flashes over the first digit of the security code number.

2. Select the required first digit with the arrow keys and press ENTER.

3. Repeat this procedure for the remaining three numbers.

Operation

If the code is correct after you press ENTER on the last digit, the sequence is
continued. If it is not correct, the instrument returns to OPERATING mode. Refer to

Section 3.7.4 for further details.

Note

Rosemount™ sets the code number to 0000 at the factory; you should change it in SET UP
mode.

4.10.2 Set averages

The instrument calculates four separate averages. These are defined in units of seconds,
minutes, hours, and days. You can use any of the four averaging stacks to provide the
instrument's analog output. You can set each averaging time within predefined limits.

1. Press ENTER when this display is shown.

The display now shows one of the averages.

2. Use the arrow keys to select the average time that you need to change and press
ENTER to change it.

You can now change the value using the arrow keys and confirm it by pressing
ENTER.

3. Set the seconds averaging stack to the required value.

This is limited to within 10 to 60 seconds in 10-second intervals.

4. Set the minutes averaging stack to the required value.

This is limited to within 1 to 60 minutes in 1-minute intervals.

5. Set the hours averaging stack to the required value.

This is limited to within 1 to 24 hours in 1-hour intervals.

6. Set the days averaging stack to the required value.

62 Rosemount CCO 5500

This is limited to within 1 to 30 days in 1-day intervals.

4.10.3 Configure O/P

You can set up the analog loop output from this mode.

1. Press ENTER while this display is shown to access it.

2. Press the arrow keys to step through the available options.

3. Press ENTER to access and change the displayed parameters of each of the six
available options listed below:

a. Output

b. Averages

c. Units

d. Output Span

e. Fault Condition

f. Set mA Output

Operation

Output

You can set an origin of 0 or 4 mA for the current loop output. The arrow keys toggle
between these two options. Press ENTER to enter the new value.

Average

You may use any of the four averaging stacks (seconds, minutes, hours, and days) for the
analog output. You can select them with the arrow keys and enter them with the ENTER
key.

Reference Manual 63

Operation

Units

The analog output can represent the gas concentration in units of mg/m3, mg/Nm3, or
vpm. The arrow keys toggle between these three options. Press ENTER to enter the new
value.

Output Span

Select the required span using the arrow keys for each digit. Press ENTER to enter the value
of each digit. The units are displayed in vpm, mg/m3, or mg/Nm3, depending on what has
been selected beforehand.

Note

Once you select Output Span, the current value is displayed for one second. The first digit of the
display then defaults to zero; thus you must re-enter the span value for the unit to function correctly.

Fault condition

If a fault condition occurs, you may set the current output of the instrument to one of the
following options:

Procedure

1. Set the output at 0 mA - ZERO.

2. Adjust the output to the calculated gas concentration even though a fault condition
exists - MEAS.

3. Hold the last selected gas concentration - HOLD.

4. Set the output to full scale (20 mA) - F.S.

Press the arrow keys to select one of these options; when the desired output is displayed,
press ENTER to confirm.

Set mA output

Note

This is set at the factory and should not be altered without due consideration.

64 Rosemount CCO 5500

Operation

From this option, the current levels of the analog output are set up. Press ENTER to select
it, and the instrument prompts you to set the current levels at 0 and 20 mA.

When this is displayed, set the current output to 0 mA as measured with a calibrated
current meter across the analog ouput loop terminals; do not connect anything else to
these terminals when setting up the output.

Use the two arrow keys to adjust the value; the UP arrow takes the current output up, and
the DOWN arrow takes it down. Press ENTER when the correct output is displayed on the
ammeter.

Note

Zero mA should be set up no matter what has been selected as the base of the current output. This is
factory set.

In a similar manner to the above, set the current output level to 20 mA.

4.10.4 Parameters

Complete the following steps to set the parameters.

1. With this option displayed, press ENTER to access the list of six available options.

The arrow keys cycle through these options.

2. When the option you need to change is displayed, press ENTER.

3. When you have made all required changes, select EXIT and press ENTER.

The six available options are:

a. Security Number

b. Identity Number

c. Path Length

d. Alarm

e. Cal. Factor

f. Plant Status Input

Reference Manual 65

Operation

Security Number

To prevent any unauthorized tampering with the setup information, it is important to
change the security code from the factory setting.

Select each digit with ENTER and change it with the arrow keys.

Note

It is important to make note of this number; otherwise, it will not be possible to change the
instrument set up.

Identity Number

If you are using the system as part of an integral monitoring system and are using the serial
input and outputs, the central processor requires a Device Identity to identify each
instrument. This number must be unique for each equipment item and can be set from 1
to 30 as required.

Path Length

Note

Once you select path length, the instrument displays the current value for one second. The first value
of the display then defaults to zero; therefore, you must re-enter the value to calculate the gas
concentrations correctly.

The transmissivity of any gas depends both on the concentration and on the path length
through which the radiation is transmitted. Similarly, the output of the Rosemount™ CCO
5500 Analyzer gas monitor also depends on the path length of the flue gas through which
the radiation is transmitted.

Refer to Section 2.4.1.

The Rosemount CCO 5500 Analyzer is sensitive to the product of concentration and path
length. In order to obtain a true value of concentration of gas, you must input the correct
path length into the processor. The processor then uses the value to produce a final value
of gas concentration.

Note

The path length entered must represent the length of the actual gas pass, not the flange to flange
dimension between the source and receiver.

66 Rosemount CCO 5500

Operation

Alarm

A contact output is available to warn of a high gas concentration. You may trigger the
contact output from any of the four averaging stacks. Select the source with the arrow key
and enter it with ENTER.

Select the units for the alarm; these may be different than the units selected for the analog
output.

After you select the source, the instrument requires a level that will trigger the output. Set
the desired level with the arrow keys.

Cal Factor

Note

First, record the original Cal Factor before entering this mode as displayed in Mode 4 → Calibration
Data. The Cal Factor is lost when the menu option is entered.

During the calibration routine, the instrument calculates a Cal Factor which sets the basic
calibration of the instrument. You may change this value from this mode.

Note

Since this value controls the calibration of the instrument, only change if necessary.

Plant Status Input

Use this to determine whether the plant is operating under correct conditions.

There is a choice of three controls for plant status: Logic Input, Serial Input, and Multiple. You
can only use one to control plant status at any one time.

Reference Manual 67

Operation

• Logic Input

If the PS1 and PS2 terminals are linked in the control unit, the logic contact is made,
and the plant status is OFF. You may link these terminals manually during a plant
shut down, or you may wire them to a switch/contact outside the unit (e.g., a value
that opens and closes the duct). Press ENTER to select this option when the Plant
Status → Serial Input option is displayed.

• Serial input

If you select this option, the criteria controlling plant status are transmitted via the
serial data link. Press ENTER when the Plant Status I/P → Serial Input option is
displayed to select this option.

• Multiple

Four options are available here. Press ENTER when the Plant Status I/P → Multiple
option is displayed, and the first option Temperature is displayed. Use the arrow keys
to toggle YES or NO. NO means that the temperature threshold is not used to
determine plant status. If you select YES, the display enters the display below.
Configure the instrument for temperature threshold. Press ENTER when it is
correctly configured, and the display moves to the next option Oxygen. After you set
the last option, the Logic Input display returns to the PARAMETERS → Plant Status I/P
option. Use the DOWN arrow to scroll down to EXIT and press ENTER. The plant
status is now full configured.

Plant status is only OFF if all options selected are registering plant status OFF. If any
one of them is not fulfilling plant status OFF conditions, then the instrument
registers plant status ON.

- Temperature

A value is set here for the temperature threshold. While the temperature (taken
from the normalizing temperature) is above the threshold value, plant status is
ON. If the temperature drops below the threshold, plant status is OFF, and only
the seconds averaging stack updates.

- Oxygen

Oxygen is set and used in a similar manner to the temperature threshold.
However, if the normalizing oxygen level rises above the threshold, plant status
is OFF. For plant status ON, the oxygen level must be below the threshold.

- Water Vapor

68 Rosemount CCO 5500

This is set and used in a similar manner to the temperature threshold. If the
normalizing water vapor level falls below the threshold, plant status is OFF. For
plant status ON, the water vapor level must be above the threshold.

- Logic Input

Select YES or NO and press ENTER. For plant status to be ON, the logic input (PS1
and PS2) must be open circuit; for plant status to be OFF, the logic input must be
closed circuit. After you configure this option, the menu exits to the Multiple
option. Use the DOWN arrow to select EXIT and press ENTER.

4.10.5 Normalization

Complete the following steps to set the Normalization parameters.

1. Press ENTER to access one of the four normalizing parameters listed below.

Operation

2. Use the arrow keys to cycle through the four options and press ENTER once the
desired option is selected.

a. Temperature

b. Oxygen

c. Pressure

d. Water Vapor

Once selected, each of the above normalizing parameters have the same suboptions: Set
Standard Levels and Set Values. Under Set Values, are three more suboptions that determine
how the instrument reads the data: Analog Input, Serial Input, and Keypad Input.

Set Standard Levels

Each normalizing parameter normalizes the measured gas concentration to standard
conditions of temperature, oxygen, pressure, and water vapor. Set these levels within this
option. Use the arrow keys to change each displayed normalizing standard value.

Temperature

Always use an analog input for temperature correction; this ensures that the flue gas
temperature is being measured continuously and accurately. Connect the analog output
of the temperatue transducer into the Rosemount™ analyzer and select the analog input
option. This value is used to normalize the gas concentration measurement and to correct
for the effects of temperature on the IR absorption spectrum.

Reference Manual 69

Operation

If you use the Keypad Input, and the gas temperature is higher than 572 ° F (300 °C), the
compensation algorithm becomes less precise, and instrument accuracy deteriorates
accordingly. Rosemount does not recommend this.

Note

If normalization is not required, the instrument must hold the temperature of the gas in the duct
using the Analog Input option.

Press ENTER with the Temperature option selected to access Set Standard Levels and Set Values.
Use the arrow keys to toggle between these options and Exit.

Set Values

You can bring the normalizing data into the instrument in one of three ways:

• Analog Input

This uses the 4-20 mA inputs within the processor to receive the measured
transducer data. The values at 4 mA and 20 mA will be requested should this option
be selected.

• Serial Input

If you use an input unit, all normalizing data can be transmitted via the serial data
line.

• You can enter a fixed value via the keypad. This is suitable where the value is stable

to about ±5%.

With an integrated system, set the lead analyzer's normalizing parameters to the 4-20 mA
inputs. Then set all the other analyzers to serial, and the normalization parameters are
transmitted down the serial data highway.

Oxygen

To correct the data to standard levels of oxygen, you must enter an estimate of the oxygen
at the point of measurement. If the oxygen level is being continuously measured, connect
the analog output of the oxygen analyzer into the Rosemount™ CCO 5500 Analyzer and
select Analog Input. You must define this input as either WET or DRY depending on how the

70 Rosemount CCO 5500

Operation

measurement is made. After you define the wet or dry, you need to define the Analog Input
values; set the 4 mA and 20 mA values. If the oxgyen level is relatively constant through all
firing conditions, you may use a fixed keypad input.

With an integrated system, you can take the oxygen data to the instrument via the serial
data line.

Note

If normalization is not required, you must set the normalizing parameters for oxygen in the
instrument.

Pressure

To correct the data to a standard pressure, normally 14.7 psi (101 kPa), you must
determine the pressure at the point of measurement. If the flue pressure is relatively
constant through all firing conditions, then you may use a fixed keypad input. If the
pressure, is not constant, measure it and bring it into the instrument via the 4-20 mA
analog input within the processor.

4.10.6

Note

If normalization is not required, set the normalizing parameters for pressure in the instrument to

14.7 psi (101 kPa)(Standard Level and Keypad Input).

With an integrated system, you can take the pressure data to the instrument via the serial
data line.

Water Vapor

An across the duct monitor measures the gas concentration under wet conditions. Unlike a
sampling system, the gas has not been preconditioned in any way before you make a
measurement.

When the water vapor is at a relatively fixed level, set the standard level to DRY to
normalize it to dry conditions. Use a fixed value in the keypad option representing the
expected water vapor produced for the fuel type. If the measurement is not to be
normalized for water vapor, set the standard level to WET.

With an integrated system, you can take the water vapor data to the instrument via the
serial data line.

Reset averages

Note

Resetting averages causes the rolling average data to be cleared from memory.

Reference Manual 71

Operation

You can reset the average values that are currently held in the four averaging stacks using
this option; this ereases the current average that is held in all of the averaging stacks.
Select this option by pressing ENTER and using the arrow keys. The instrument requests
confirmation before the averages are reset.

Note

If you select this option, all the data in the averaging stacks is reset, and the data for as much as 30
days is lost.

4.10.7 Calibrate

From this option, you may display the two detector levels and conduct a basic calibration.
While in this mode, the gas cell is not moved; this gives an immediate response for setting
up the detector levels. A Cal Factor that is calculated during a calibration routine sets the
basic calibration of the instrument. Press ENTER while this is displayed to see the following
options:

1. Set Detectors

2. Span Adjust

3. Calibrate

Set detectors

You can display both the D1 and D2 levels; you can also display saturation counts. To give
an immediate response to any alterations that are required, the filters and gas cells are not
moved during this operation.

Refer to Section 3.5 for a discussion of the detector level and saturation count.

Span adjust

Note

Rosemount™ initially sets the span factor at the factory; do not adjust it unless the instrument
sensitivity is suspected. In any case, Rosemount recommends that you record the orginal value
before making adjustments.

72 Rosemount CCO 5500

Operation

You can adjust instrument sensitivity if a known concentration of gas exists between the
source and receiver units and instrument sensitivity is supsected. If a problem arises,
consult Rosemount.

You may need to adjust the span factor if you have fitted new gas cells or filters.

Calibrate

Re-enter the Mode 5 CALIBRATE menu and proceed to the Calibrate option.

You can calculate the basic calibration of the instrument from this routine. It is preferable
to conduct this operation with the plant shut down to ensure a zero gas concentration
within the duct. If this is not possible, the instrument can calibrate to a known value of the
gas concentration - the calibration target.

Set the calibration target either to a known value of the gas concentration or to zero. Then
set the desired number of cycles over which the calibration factor is determined
(Rosemount™ recommends a minimum of 30). Now run the calibration, and the display will
show a countdown during its execution. When the calibration is complete, the new Cal
Factor is displayed for about five seconds, and the instrument exits the calibration routine.

Note

You must run the calibration routine during commissioning; otherwise, the instrument will not be
able to calculate the true level of gas within the duct.

Reference Manual 73

Operation

Do not run the calibration routine unless reasonable conditions exist in the duct. If it is not
the initial calibration, record the Cal Factor from the Parameters option before running the
calibration.

To aid configuration and to record any subsequent changes to the operating parameters,

#xd_5bc5da84c7ce5b06--2a6d55ac-163c9dfb12c--7ead/table_jlb_4y5_b2b lists all of the

options available and can be used as a record of the operating parameters.

Instrument SettingsTable 4-1:

Parameter Config

Averages

Seconds

Minutes

Hours

Days

Output

0 or 4 mA base

Units

Average

Fault condition

Parameters

Path length

Alarm source

Alarm units

Alarm levels

Normalization

Temperature

Standard level °F (°C)

I/P °F (°C) @ 4 mA

I/P °F(°C) at 20 mA

Keypad input °C (not ideal)

Serial input

Oxygen

Standard level %

Wet or dry gas

I/P % @ 4 mA

I/P % @ 20 mA

Keypad input %

Serial input

74 Rosemount CCO 5500

Operation

Instrument Settings (continued)Table 4-1:

Parameter Config

Pressure

Standard level psi (kPa)

I/P psi (kPa) @ 4 mA

I/P psi (kPa) @ 20 mA

Keypad input

Serial input

Water vapor

Standard level (wet %/dry

Keypad input %

Measured value

After the calibration is conducted, a cal factor is calculated; this determines the calibration
of the instrument. The cal factor is displayed for a few seconds after a calibration has been
conducted, and you can aslo interrogate it from Mode 4 (DIAGNOSTIC mode). Enter the cal
factor into the table below as a record of instrument operation.

Note

Rosemount™ obtained factory settings under the following conditions:

• 2 m path length

• Clean conditions

Calibration DataTable 4-2:

Detector outputs Factory Config

D2

D1

E1

E2

Calibration data

Cal factor

Span factor

Output calibration

Set zero

Set span

Reference Manual 75

Operation

4.11 Check Cell mode

Use this mode with a Rosemount™ check cell. It verifies calibration and operation of the
analyzer.
For details for this mode's use, refer to Section 4.13.1.

Procedure

1. Press ENTER on viewing this display if you need to use the CHECK CELL mode.

2. Use the arrow keys to toggle the display to YES and press ENTER again.

You have now selected the CHECK CELL mode. Note that the display will default back
to Mode 1 if you don't select YES within five seconds. Do not insert a the check cell
before accessing this option. Refer to Section 4.13.1.

4.12 Shutdown procedure

You do not need to shut down the system unless you are performing maintenance.

1. In this case, power down the power supply (and thus the control unit and analyzer
heads).

2. Close the manually operated isolating valves on the analyzer heads.

3. Proceed with service.

4. When completed, open the valves and power up the system.

Postrequisites

You may need to calibrate the system depending on the type of maintenance you are
doing. For details, refer to Chapter 6

4.13

4.13.1 Notes for using a Rosemount™ check cell

Routine checks

The check cell and holder are optional items available from Rosemount. Rosemount has
designed the check cell to verify the reading of Rosemount cross duct analyzers. When
placed within the measurement path, the check cell can generate a known increase in gas
concentration.

76 Rosemount CCO 5500

Operation

Prerequisites

Note

Place the check cell at the receiver side.

Measurement conditions

For absolute verification, you must check the instrument when no measurement gas is
present. If a background concentration of measurement gas is present, an increase will still
be generated, but the net effect will be complex.

Mode 6

The ideal time to perform a check cell test is with the plant off, auto zero condition on, and
the analyzer well stabilized at zero. Do not insert the check cell in any other mode than
Mode 6.

The analyzer does not update rolling averages while in Mode 6.

Procedure

1. Enter Mode 6 on the control unit before inserting the check cell into the analyzer.
Press ENTER when Mode 6 is displayed.

2. Use an arrow key to toggle from NO to YES and press ENTER to access the check cell
function.

If you don't select this within five seconds, the instrument returns to the normal
OPERATING mode.

3. When you see this option, insert the check cell observing the procedure outlined
below.

4. Remove the two screws retaining the cover on the check cell holder (Figure 4-4).

Reference Manual 77

Operation

Check Cell HolderFigure 4-4:

A. Check cell cover
B. Receiver
C. Check cell holder

5. Insert the check cell into the check cell holder and replace and tighten the screws.

You can insert the cell in either direction. Refer to Figure 4-5.

Check CellFigure 4-5:

A. Gas cell window

Introducing the check cell may cause an initial major disturbance to the instrument
operation.

6. Wait for the instrument reading to settle (five to ten minutes) and record the gas
measurement with the cell in position.

7. Remove the check cell and wait for the analyzer to return to zero (another five to ten
minutes).

8. Replace the cover on the check cell holder and place MODE on the control unit.

The instrument now returns to OPERATING mode.

78 Rosemount CCO 5500

You can do this test with the plant on line, but any pollutant gas present (it will probably be
residing at a different temperature) will interfere with the check cell value.

Note

Do not insert the check cell in any other mode as this will influence the recorded rolling averages.

Rosemount fixes the calibration of the Rosemount CCO 5500 Analyzer at the point of
manufacture. If gross errors exist, this could suggest an instrument malfunction. If you
observe minor errors, please check the procedure and if necessary, return the gas cell for
recertification.

4.13.2 Alarms and emergency conditions

The alarm thresholds for the system are set as described in the normal OPERATING mode.
When an alarm condition occurs, the red LED on the control unit lights up. This goes out
when the alarm condition has cleared. When the condition has cleared, the software
records the fact that an alarm condition occurred. The 4 to 20 mA output from the
analyzer will also alter according to the pollution levels detected.

Operation

4.13.3 Emergency shutdown procedure

This is the same as normal shutdown.

1. Remove power from the power supply.

The whole system closes down.

2. Close the isolating valves if required and stop the flow of air to the air purges.

4.13.4

Isolation procedure

Complete the following steps to isolate the analyzer.

1. Shut down power to the power supply.

2. Shut off compressed air to the air purges and close the isolating valves.

Reference Manual 79

Operation

80 Rosemount CCO 5500

5 Maintenance

5.1 Preventative maintenance

Rosemount designs this equipment to keep maintenance to an absolute minimum.

5.1.1 Cleaning windows

It is important that you keep the optical windows of both the source and receiver
reasonably clean. Keep any mounting tubes free from build-up of dust and fly ash.
Clean the optical window (Figure 5-1) every six months and more frequently for dirty
processes.

Optical WindowFigure 5-1:

Maintenance

A. Air purge
B. Source
C. Window

WARNING!

HIGH TEMPERATURE AND DANGEROUS VAPORS
Take great care when removing the Rosemount™ CCO 5500 Analyzer from a positive pressure
stack or duct. The source may be very hot, and there may be dangerous vapors present.
Observe all required safety practices.

Procedure

1. Unbolt and remove the source and receiver from their air purges.

2. Wipe the windows with a soft dry cloth.

Reference Manual 81

Maintenance

5.2 Corrective maintenance

The following maintenance procedures describe the necessary steps for removing and
replacing failed elements of the Rosemount™ CCO 5500 Analyzer.

WARNING!

ELECTRIC SHOCK
Install all protective equipment covers and safety ground leads after equipment repair or
service. Failure to install covers and ground leads could result in serious injury or death.

5.2.1 Replace heater element

The heater element has a finite life and at some stage you will have to replace it.
Rosemount™ designed the unit to give a minimum of two years continuous operation; you
can replace the heater element on site when necessary.
Replace a failed heater element according to the following procedure.

Procedure

1. Shut down and lock out power to the Rosemount CCO 5500 Analyzer.

2. Unbolt and remove the source unit from the air purge.

3. Loosen the source unit cable gland (Figure 5-2) so the cable can slip when the rear
cover plate is removed.

Source Rear Cover PlateFigure 5-2:

A. Rear cover plate
B. Cable gland

4. Unsccrew and remove the rear cover plate.

5. Unscrew and remove the circuit board (Figure 5-3).

82 Rosemount CCO 5500

Source Unit Circuit BoardFigure 5-3:

A. Circuit board mounting screw
B. Circuit board

Maintenance

6. Remove the terminal nuts (Figure 5-4) and remove the heater wires.

Heater ElementFigure 5-4:

A. Terminal nuts
B. Captive screw
C. Heater

7. Unscrew the three captive screws.

8. Remove and discard the heater assembly.

9. Install the new heater assembly and tighten the three captive screws.

Reference Manual 83

Maintenance

10. Install the two wires and terminal nuts removed in Step 6.

11. Install the circuit board and retaining screws removed in Step 5.

12. Install and fasten the rear cover plate.

13. Power up the Rosemount CCO 5500 Analyzer and allow fifteen minutes for the
heater to reach operating temperature.

The analyzer starts to monitor the gas levels.

5.2.2 Replace chopper motor assembly

Complete the following steps to replace the chopper motor assembly in the analyzer.

1. Shut down and lock out power to the Rosemount™ CCO 5500 Analyzer.

2. Unbolt and remove the source unit from the air purge.

3. Remove the window plate (Figure 5-5) from the source unit.

Source Unit Circuit Board and Center Plate AssemblyFigure 5-5:

A. Black wire (M-)
B. Red wire (M+)
C. Window plate
D. Circuit board and center plate assembly
E. Brass screws

84 Rosemount CCO 5500

Maintenance

4. Unscrew the three brass screws that secure the circuit board and center plate
assembly.

5. Lift the circuit board and center plate assembly out of the source unit.

6. De-solder the red and black chopper motor power wires from the circuit board.

7. Unscrew and remove the three chopper motor screws (Figure 5-6).

Chopper Motor AssemblyFigure 5-6:

A. Chopper motor assembly
B. Chopper motor retaining screws
C. Center plate

8. Install the new chopper motor and retaining screws removed in Step 7.

9. Solder the chopper motor power wires to the circuit board. Solder the red wire to
the M+ terminal and the black wire to the M- terminal.

10. Install the center plate and circuit board assembly. Secure the assembly with the
three brass crews removed in Step 4.

11. Line up and install the window plate onto the source unit. Fully seat the window
plate flange in the source unit.

12. Secure the source unit to the air purge using the four screws removed in Step 2.
Tighten the screws evenly.

13. Power up the Rosemount CCO 5500 Analyzer and check the chopper motor
frequency in Mode 4 (DIAGNOSTICS). Adjust using the trim potentiometer as
described in Section 3.6.

Reference Manual 85

Maintenance

5.2.3 Replace source unit gas cell

Replace the source unit gas cell according to the following procedure.

1. Shut down and lock out power to the Rosemount™ CCO 5500 Analyzer.

2. Unbolt and remove the source from the air purge.

3. Remove the window plate (Figure 5-5) from the source unit.

4. Unscrew the three brass screws that secure the circuit board and center plate
assembly.

5. Lift the circuit board and center plate assembly out of the source unit.

6. Loosen the setscrew at the end of the gas cell assembly (Figure 5-7).

Source Gas CellFigure 5-7:

A. Gas cell
B. Setscrew

7. Pry the gas cell from the stepper motor shaft.

8. Insert a new gas cell onto the stepper motor shaft and tighten the setscrew.

9. Install the center plate and circuit board assembly and secure with the three brass
screws removed in Step 4.

10. Line up and install the window plate onto the source unit. Fully seat the window
plate flange in the source unit.

86 Rosemount CCO 5500

11. Secure the source unit to the air purge using the four screws removed in Step 2.
Tighten the screws evenly.

12. Power up and recalibrate the Rosemount CCO 5500 Analyzer.

Refer to Calibrate.

5.2.4 Replace receiver unit gas cell

Replace the receiver unit gas cell according to the following procedure.

1. Shut down and lock out power to the Rosemount™ CCO 5500 Analyzer.

2. Unbolt and remove the receiver unit from its air purge.

3. Loosen the receiver unit cable gland so the cable can slip when the window plate is
removed.

4. Unscrew and pull the window plate (Figure 5-8) from the front of the receiver unit.

Receiver Gas CellFigure 5-8:

Maintenance

A. End detector PCB
B. Window plate
C. M6 bolts
D. M4 x 16 screws
E. Side detector PCB
F. Gas cell assembly

5. Use a marker pen to match-mark all components of the receiver stack.

6. Remove the four M4x16 screws that secure the side detector PCB to the receiver
stack.

Reference Manual 87

Maintenance

7. Remove the four M6 bolts that secure the detector stack components.

8. Observe the orientation of the gas cell assembly in the detector stack.

9. Slide the gas cell assembly out of the detector stack.

10. Replace the gas cell using the same orientation observed in Step 8.

(The notch in the gas cell assembly should be nearest to the large circuit board
secured to the detector stack).

11. Place the end detector on top of the detector stack.

CAUTION!

EQUIPMENT DAMAGE

Do not overtighten the detector stack mounting bolts. Over-tightening the mounting
bolts may fracture the gas cell.

12. Install and gently tighten the M6 mounting bolts removed in Step 7.

13. Position the side detector against the receiver stack. Install and tighten the M4x16
side detector mounting screws.

14. Line up and install the window plate onto the receiver unit. Fully seat the window
plate flange in the receiver unit.

15. Secure the receiver unit to the air purge using the four screws removed in Step 2.
Tighten the screws evenly.

16. Power up and recalibrate the Rosemount CCO 5500 Analyzer.

5.2.5

5.3

Refer to Calibrate.

Electronics

The electronics require no routine maintenance. They are all solid state and undergo a
rigorous factory burn-in procedure. If there is any doubt about the electronics'
performance, interrogate the control unit from the keypad to determine whether or not
they are functioning properly.

Refer to Chapter 6.

Adjust span factor

The span factor does not require periodic adjustment. However, if either of the following
repair actions are performed, you may need to adjust the span factor.

• Gas cell changed either in the receiver or source.

• Interference filter changed in the receiver.

Use the following procedure to adjust the span factor.

88 Rosemount CCO 5500

Maintenance

Procedure

1. At the control unit keypad, select Mode 5 → Configure O/P → Set Span.

2. Set the span factor to 1000.

3. Calibrate the analyzer under zero conditions.

Refer to Calibrate.

4. Select Mode 5 → Normalization. Set the temperature to 68 °F (20 °C).

5. Select Mode 5 → Parameters → Pathlength to enter the 3.28 ft. (1 m) path length.

Note

The check cell reading must be less than 999 ppm￭m. If greater than 999 ppm￭m, you must
enter a larger path length to reduce the effective ppm￭m value of the check cell. Select a path

length such that ppm￭m/path length is less than 999.

6. Select Mode 5 → Configure O/P → Set Span. Enter the span factor indicated for the
check cell in Mode 6. If this value exceeds 999 ppm, divide by the path length

entered above to determine the span.

7. Press ENTER and wait for the second reading to appear under the span factor option.

5.3.1

This should read the same as the value entered in Step 6.

8. Using the up and down arrow keys, adjust the span factor until the second reading
agrees with the certified check value (divided by the path length if appropriate).

9. Record the span factor and press ENTER.

10. Confirm the span factor by selecting Mode 2 → Parameters → Span Factor and
checking the value.

Reset span factor

An example of resetting the span factor is outlined below.

1. You insert a certified check cell of 2880 ppm into the check cell holder with the
analyzer in Mode 6. You take a reading of 3240.

Due to the value of the check cell exceeding 999 ppm, you need to use a suitable
path length to reduce the effective value of the check cell.

2. In this case, you choose a path length of 13.1 ft. (4 m); thus the effective value of the
check cell is 720 ppm (2880/4).

However, in Mode 6 it reads higher (3240); this value is effectively 810 ppm at a 13.1
ft. (4 m) path length.

3. You key 810 in as the first value in the span factor option.

4. Then you adjust the span factor until the second value reads 720.

5. Press ENTER to set the span factor.

Reference Manual 89

Maintenance

90 Rosemount CCO 5500

6 Troubleshooting

6.1 Finding faults with the keypad

WARNING!

ELECTRIC SHOCK
Install all protective equipment ground covers and safety ground leads after troubleshooting.
Failure to install covers and ground leads could result in serious injury or death.

If a fault occurs, the control unit display switches from its current mode of operation to the
DIAGNOSTICS mode and displays the current fault condition. Refer to Section 6.1.1 for
further information on the fault conditions. If the fault clears, the display stays in
DIAGNOSTICS mode and displays All Clear.

Enter DIAGNOSTICS mode from the instrument's keypad; you can do this at any time
without interrupting or disturbing the analog outputs of the equipment. As an initial guide
to equipment performance, typical values for instrument operation are given below.

Troubleshooting

Rosemount
CCO 5500

6.1.1

D2 min

™

3,000 20,000 3,000 20,000 2,000 2,900

where:

Modulation frequency = 30 to 45 Hz

Mark/space ratio = 0.9 to 1.1

Saturation count = 50 maximum for all analyzers

If the values are outside of the above ranges, the Data valid LED extinguishes, and the fault
condition is displayed.

D2 max D1 min D1 max Set Cal min Set Cal max

Data valid LED out

If one or more fault conditions occur, the data valid LED on the front panel extinguishes,
the data valid relay operates, and the instrument automatically enters the DIAGNOSTICS
mode to display the fault condition.

Fault ConditionsTable 6-1:

Fault condition Possible causes

Detector signal saturated (Sat # over 50) Incorrect detector gain adjustment.

Reference Manual 91

Troubleshooting

Fault Conditions (continued)Table 6-1:

Fault condition Possible causes

Instrument condition during high opacity condi­tions which have now cleared.

Low detector levels (D1 < 3,000) High opacity in duct.

Dirty windows.

Incorrect detector gain adjustment.

Cal factor out of range Calibration conducted during unstable duct

conditions.

Poor alignment.

Incorrect detector gain adjustment.

Modulation frequency is below 30 Hz or above
45 Hz.

Reference signal failure Chopper motor fails.

Poor supply voltage.

Faulty chopper motor.

Incorrect setting within the source unit.

6.2

Note

If the instrument recognizes a fault condition, it does not update the minutes, hours, and day
averages.

Troubleshooting tables

The troubleshooting tables provide fault diagnosis, possible causes, and the appropriate
actions if you suspect an instrument fault. Note the symptoms and when the fault has
occurred. Refer to the appropriate tables.

Note

Be sure to use the tables from the top down and pay particular attention when "proceed to next test"
and "proceed to next possible cause" are indicated.

The troubleshooting tables indicate which of the four units failed:

• Source unit

• Control unit

• Receiver unit

• Power supply unit

You can then return the faulty unit to Rosemount™ for repair.

92 Rosemount CCO 5500