Rosemount Manual: CCO 5500 Carbon Monoxide (CO) Analyzer-Rev 1.0 | Rosemount 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
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