Emerson Rosemount FCL-01 Reference Manual
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Emerson Rosemount FCL-01 Reference Manual

Emerson Rosemount FCL-01 Reference Manual

Free chlorine system with rosemount 56 transmitter
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Reference Manual
00809-0200-3412, Rev AB
October 2023
Rosemount
™
FCL
Free Chlorine System with Rosemount 56 Transmitter

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Summary of Contents for Emerson Rosemount FCL-01

  • Page 1 Reference Manual 00809-0200-3412, Rev AB October 2023 Rosemount ™ Free Chlorine System with Rosemount 56 Transmitter...
  • Page 2 Essential instructions Read this page before proceeding! Your instrument purchase from Emerson is one of the finest available for your particular application. Emerson designs, manufactures, and tests its products to meet many national and international standards. Experience indicates that its performance is directly related to the quality of the installation and knowledge of the user in operating and maintaining the instrument.
  • Page 3  CAUTION Radio interference This product generates, uses, and can radiate radio frequency energy and thus can cause radio communication interference. Improper installation or operation may increase such interference. As temporarily permitted by regulation, this unit has not been tested for compliance within the limits of Class A computing devices, pursuant to Subpart J of Part 15 of FCC rules, which are designed to provide reasonable protection against such interference.

  • Page 5: Table Of Contents

    Reference Manual Contents 00809-0200-3412 October 2023 Contents Chapter 1  Installation..........................7 1.1 Unpacking and inspection......................7 1.2 General installation information....................7 1.3 Sample requirements......................... 8 1.4 Mounting, inlet, and drain connections................... 8 1.5 Install the sensor(s)........................10 Chapter 2  Wiring............................11 2.1 Wire power..........................11 2.2 Wire analog outputs......................... 11 2.3 Wire alarm relays........................13 2.4 Wire sensor..........................
  • Page 6 10.2 Read and troubleshoot Fault and Warning messages............51 10.3 Use sensor diagnostics......................52 10.4 Troubleshoot calibration problems..................52 10.5 Troubleshooting chlorine measurement errors..............53 10.6 Troubleshooting - pH......................55 10.7 Other troubleshooting - general................... 57 10.8  Simulate chlorine inputs......................58 10.9 Simulate pH input........................59 10.10 Simulating inputs - temperature..................60 Emerson.com...

  • Page 7: Chapter 1 Installation

    2. If there is no apparent damage, then unpack the container(s). 3. Ensure that all items shown on the packing list are present. If items are missing, then notify Emerson immediately. 1.1.1  Rosemount FCL-01 (free chlorine without continuous pH correction) The FCL-01 consists of the following items mounted on a back plate.

  • Page 8: Sample Requirements

    For FCL-02 (free chlorine with continuous pH adjustment), you must also install the pH sensor. Figure 1-1: FCL-01 Dimensions are shown with inches above and millimeters below. A. Chlorine sensor B. Inlet C. Drain Emerson.com...
  • Page 9 Reference Manual Installation 00809-0200-3412 October 2023 Figure 1-2: FCL-02 Dimensions are shown with inches above and millimeters below. A. pH sensor B. Chlorine sensor C. Inlet D. Drain A ¼-in. outer dimension (OD) tubing compression fitting is provided for the sample inlet. If desired, you can remove the compression fitting and replace it with a barbed fitting.

  • Page 10: Install The Sensor(S)

    3. Confirm that sample is flowing through the flow cells. 1.5  Install the sensor(s) Emerson provides the Rosemount FCL with the sensor cable pre-wired to the transmitter. Procedure 1. Connect the chlorine sensor (499ACL-01-54-VP) to the cable labeled CL. 2. Connect the pH sensor (3900-VP-02-10) to the cable labeled pH.

  • Page 11: Chapter 2 Wiring

    Reference Manual Wiring 00809-0200-3412 October 2023 2  Wiring 2.1  Wire power Wire AC mains power supply to the power supply board, which is mounted on the left hand side of the transmitter enclosure beneath the gray plastic cover.  WARNING Electrical shock Electrical installation must be in accordance with the National Electrical Code (American National Standards Institute [ANSI]/National Fire Protection Association [NFPA]-70) and/or any other applicable national or local codes.
  • Page 12 B. To power supply PCB (ribbon cable) C. To digital I/O communication board D. To sensor 1 signal board E. To sensor 2 signal board The analog outputs are on the main board near the hinged end of the enclosure door. Emerson.com...

  • Page 13: Wire Alarm Relays

    Reference Manual Wiring 00809-0200-3412 October 2023 For best EMI/RFI protection, use shielded output signal cable enclosed in earth-grounded metal conduit. Keep output signal wiring separate from power wiring. Do not run signal and power or relay wiring in the same conduit or close together in a cable tray. 2.3 ...

  • Page 14: Wire Sensor

    NEXT and press ENTER/MENU. 2. The next screen lists navigation rules. Press ENTER/MENU for the next screen. 3. Configure sensor 1. Sensor 1 is the free chlorine sensor. The screen has three control boxes. a) For measurement, choose Free chlorine. Emerson.com...
  • Page 15 If you have a Rosemount FCL-01 (no pH sensor), enter the pH of the process liquid in the third control box.
  • Page 16 Wiring Reference Manual October 2023 00809-0200-3412 Emerson.com...

  • Page 17: Display And Operation

    Reference Manual Display and operation 00809-0200-3412 October 2023 3  Display and operation 3.1  Main display The transmitter has a four line display. Figure 3-1. The display can be customized to meet your requirements. Fault or warning messages, if appropriate, appear at the bottom of the screen. See Overview of troubleshooting.

  • Page 18: Keypad

    Pressing the ENTER/MENU key will bring up the main Menu only if the main display is showing. Note that the current reading and temperature for sensor 1 ( ) and sensor 2 ( ), if applicable, always appear at the top of the screen. The cursor (dark blue backlit field) is on Calibrate. Emerson.com...
  • Page 19 Reference Manual Display and operation 00809-0200-3412 October 2023 2. Press Down to move the cursor to Program. 3. Press ENTER/MENU. The cursor is on Outputs, and the first screen in the Outputs submenu is showing. 4. To select a different program submenu, use Right to move the cursor to the desired tab and press ENTER/MENU.
  • Page 20 The information screen for Dampening is shown below. 12. To close the information screen, press any key. A NEXT and BACK button are at the bottom of the screen. NEXT means that additional control boxes are available on at least one or more screen. Emerson.com...

  • Page 21: Hold

    Reference Manual Display and operation 00809-0200-3412 October 2023 13. To view the next screen, use the navigation keys (either Down or Right) to move the cursor to NEXT and press ENTER/MENU. The next screen in the Outputs submenu appears. The cursor is on the Outputs tab. 14.

  • Page 22: Main Display

    A message stating which sensors are in hold appears in the fault/warning banner at the bottom of the display. 3.5  Main display 3.5.1  Configuring the main display The main display can be configured to meet your specific requirements. Procedure 1. With the main display showing, press ENTER/MENU. The main menu appears. Emerson.com...
  • Page 23 Reference Manual Display and operation 00809-0200-3412 October 2023 2. Choose Display Setup. The screen below appears. 3. Move the cursor to Display setup and press ENTER/MENU. The screen below appears. 4. Choose Configure main display. The screen below appears. The position of each control box corresponds to the position of the variable in the main display.

  • Page 24: Security

    If the entry is correct, the requested submenu appears, and you have access to all the submenus the code entitles you to. If the entry is wrong, the Invalid code screen appears. 3.6.2  Assigning security codes See Security. 3.6.3  Bypass security codes Call the factory. Emerson.com...

  • Page 25: Programming The Transmitter

    Reference Manual Programming the transmitter 00809-0200-3412 October 2023 4  Programming the transmitter 4.1  Entering the Program menus Complete the following steps to access the Program menus on your 56 Transmitter. Procedure 1. With the main display showing, press ENTER/MENU to display the main menu. 2.

  • Page 26: Outputs

    Move the cursor to the appropriate control box and press the desired setting. For more information about the control box the cursor is on, press INFO. To close the information screen, press any key. 4.3  Relays 4.3.1  Menu tree Figure 4-2 is the Relays menu tree. Emerson.com...
  • Page 27 Reference Manual Programming the transmitter 00809-0200-3412 October 2023 Figure 4-2: Menu tree for the Relays submenu 4.3.2  Configure relay settings A large number of relay actions are available in the Rosemount 56. Procedure 1. For more information about a relay action, move the cursor to Explanation of relay actions button and press ENTER/MENU.

  • Page 28: Measurement

    6. Move the cursor to the appropriate control box and make the desired setting. 7. For more information about the control the cursor is on, press INFO. 8. To close the information screen, press any key. 4.4  Measurement 4.4.1  Menu tree Figure 4-3 is the Measurement menu tree. Emerson.com...

  • Page 29: Temperature

    Reference Manual Programming the transmitter 00809-0200-3412 October 2023 Figure 4-3: Menu tree for the Measurement submenu Measurement Sensor 1 or 2 Sensor 1 (Cl) Sensor 2 (pH) Measurement Pre-amplifier location Filter Units Reference impedance Wiring pH correction Resolution Filter Solution temperature correction Dual slope calibration A.

  • Page 30: Ph Diagnostic Setup

    Figure 4-5: Menu tree for the pH diagnostic setup submenu pH diagnostics Sensor 2 (pH) Maximum allowed offset Minimum allowed slope Maximum allowed slope Sensor diagnostics on/off Ref fault high Glass fault high Sensor diagnostics on Glass impedance temp correction on/off Glass impedance measurement method Emerson.com...

  • Page 31: Security

    Reference Manual Programming the transmitter 00809-0200-3412 October 2023 4.6.2  Configure pH settings Complete the following steps to set up the pH diagnostics on the Rosemount 56 Transmitter. Procedure 1. Move the cursor to the appropriate control box and make the desired setting. 2.
  • Page 32 Programming the transmitter Reference Manual October 2023 00809-0200-3412 Emerson.com...

  • Page 33: Chapter 5 Calibration

    Reference Manual Calibration 00809-0200-3412 October 2023 5  Calibration 5.1  Calibrate menu The Calibrate menu allows you to do the following: 1. Calibrate the RTD (temperature sensing element) in the chlorine and pH sensors. 2. Calibrate the pH sensor. Four methods are available: a.

  • Page 34: Calibrating Temperature

    Be sure the sensor is installed in the flow cell in the FCL and the sample is flowing down the inside tube of the overflow sampler. Important If you are calibrating the FCL-02, calibrate the pH sensor first and install it in its flow cell before calibrating the free chlorine sensor. Emerson.com...

  • Page 35: Calibrate The Ph Sensor

    Reference Manual Calibration 00809-0200-3412 October 2023 If the calibration is successful, the transmitter displays the Calibration complete screen and the sensitivity (nA/ppm). The screen also shows the typical sensitivity range for the sensor and the recommended acceptance criterion. You are asked to accept the calibration.
  • Page 36 Procedure 1. With the main display showing, press ENTER/MENU to display the main menu. 2. Move the cursor to Reset and press ENTER/MENU. 3. Check the desired boxes and press APPLY. Emerson.com...

  • Page 37: Chapter 6 Digital Communications

    Reference Manual Digital communications 00809-0200-3412 October 2023 6  Digital communications The Rosemount 56 Transmitter supplied with the FCL has HART communications as a standard feature. For more information, refer to the Rosemount 56 HART Addendum Manual. Rosemount FCL 56...
  • Page 38 Digital communications Reference Manual October 2023 00809-0200-3412 Emerson.com...

  • Page 39: Data And Event Logging And Retrieval

    Reference Manual Data and event logging and retrieval 00809-0200-3412 October 2023 7  Data and event logging and retrieval 7.1  Data and event logging overview Data and event logging is a standard feature in the Rosemount 56 Transmitter. However, the operator must enable the feature. When data and event logging is enabled, the 56 Transmitter will automatically store the following events with date and time stamp: •...

  • Page 40: Configure Data And Event Logging And Retrieval

    1. To download data or events, move the cursor to the Download tab and press ENTER/ MENU. 2. Unscrew the USB port cover in the lower right hand corner of the front panel and insert a USB flash drive in the port. 3. Press the appropriate button to download data or events. Emerson.com...

  • Page 41: View Events

    Reference Manual Data and event logging and retrieval 00809-0200-3412 October 2023 Downloading may take as long as 20 minutes. During download, the display and keypad are frozen, but all other transmitter functions continue. Downloaded data and events are stored in a spreadsheet. There is a separate spreadsheet for every day of data.
  • Page 42 Data and event logging and retrieval Reference Manual October 2023 00809-0200-3412 Emerson.com...

  • Page 43: Chapter 8 Graphical Display

    Reference Manual Graphical display 00809-0200-3412 October 2023 8  Graphical display 8.1  Graphical display overview The Rosemount 56 Transmitter has a dual graphical display. You can configure each graph to meet your requirements, although the time axis on both graphs must be the same. You can set the time scale to: •...
  • Page 44 The time axis can be expanded or shrunk. 4. To expand the time scale, use Left or Right to move the pair of dotted green lines to the area of interest. Press Up to expand the graph. To shrink the time axis, press Down. Emerson.com...

  • Page 45: Chapter 9 Maintenance

    Reference Manual Maintenance 00809-0200-3412 October 2023 9  Maintenance 9.1  Replace sensor circuit board The transmitter used with the Rosemount FCl requires little routine maintenance. ™ Clean the transmitter case and front panel by wiping with a clean soft cloth dampened with water only.
  • Page 46 Rinse thoroughly with water. 7. Wrap the plug with two turns of pipe tape and set aside. 8. Prepare a new membrane. a) Hold the membrane assembly with the cup formed by the membrane and membrane holder pointing up. Emerson.com...

  • Page 47: Ph Sensor

    Reference Manual Maintenance 00809-0200-3412 October 2023 b) Fill the cup with electrolyte solution. c) Wait for the wooden ring to soak up the solution. This usually takes several minutes. 9. Hold the sensor at about a 45° angle with the cathode end pointing up. 10.

  • Page 48: Constant Head Flow Controller

    9.4.3  Other maintenance Table 9-2 Figure 9-1 show the replacement parts for the flow controller assembly used in the Rosemount FCL-01. Table 9-3 Figure 9-2 show replacement parts for the flow controller assembly used in the FCL-02. Emerson.com...
  • Page 49 Reference Manual Maintenance 00809-0200-3412 October 2023 Figure 9-1: FCL-01 constant head flow controller assembly replacement parts Table 9-2: FCL-01 constant head flow controller assembly replacement parts Location in Description Figure 9-1 24039-00 Flow cell for chlorine sensor with bubble shedding nozzle 24040-00 O-ring kit, two 2-222 and one 2-024 silicone O-rings with lubricant 33812-00...
  • Page 50 O-ring kit, two 2-222 and one 2-024 silicone O-rings with lubricant 33812-00 Dust cap for constant head flow controller 9322032 Elbow, ¼-in. FNPT x ¼-in. OD tubing 9350029 Check valve, ¼-in. FNPT 33823-00 Outside tube for constant head device 24034-00 Flow Train for FCL-02 (Includes Panel) Emerson.com...

  • Page 51: Chapter 10 Troubleshooting

    Reference Manual Troubleshooting 00809-0200-3412 October 2023 10  Troubleshooting 10.1  Overview of troubleshooting When the transmitter identifies a problem the word warning or fault appears intermittently at the bottom of the display. To read a fault or warning message and troubleshooting information, press INFO. Read and troubleshoot Fault and Warning messages.

  • Page 52: Use Sensor Diagnostics

    3. For more information about a specific diagnostic measurement, move the cursor to the diagnostic of interest and press INFO. 10.4  Troubleshoot calibration problems Alert If a calibration attempt results in an error or a likely error, the transmitter displays the appropriate Warning screen. Recommended action For troubleshooting suggestions, press INFO. Emerson.com...

  • Page 53: Troubleshooting Chlorine Measurement Errors

    Reference Manual Troubleshooting 00809-0200-3412 October 2023 10.5  Troubleshooting chlorine measurement errors Although you can access troubleshooting information in the transmitter by pressing INFO, the transmitter does not display troubleshooting information for process measurement problems. Table 10-1: Chlorine measurement errors Problem See section Process readings are erratic.
  • Page 54 Check that the holes at the base of the cathode stem are open. Use a straightened paper clip to clear blockages. Zero current is unstable b) Replace the electrolyte solution. 5. Replace the sensor. Emerson.com...

  • Page 55: Troubleshooting - Ph

    Reference Manual Troubleshooting 00809-0200-3412 October 2023 10.5.4  Chlorine readings spike following sudden changes in pH (automatic pH correction) Changes in pH alter the relative amounts of hypochlorous acid (HOCl) and hypochlorite ion (OCl¯) in the sample. Because the sensor responds only to HOCl, an increase in pH causes the sensor current (and the apparent chlorine level) to drop even though the actual free chlorine concentration remains constant.
  • Page 56 4. Check for extra ground connections or induced noise. To avoid induced noise in the sensor cable, run it as far away as possible from power cables, relays, and electric motors. If ground loop problems persist, consult the factory. An experienced service technician may need to solve the problem. Emerson.com...

  • Page 57: Other Troubleshooting - General

    Reference Manual Troubleshooting 00809-0200-3412 October 2023 10.6.4  pH readings are moderately noisy and tend to wander Potential cause pH readings that are moderately noisy (±0.1 pH) and tend to wander are probably caused by bubbles getting trapped against the pH sensor. Although the overflow sampler is designed to allow bubbles to escape before they reach the pH sensor, and the sensor itself is designed so trapped air bubbles don't interfere with the measurement, bubbles may occasionally be a problem.

  • Page 58: Simulate Chlorine Inputs

    . The input current is the second line in the display. 1 information 4. Change the decade box resistance and verify that the correct current is shown. Calculate current from the equation: The voltage of a fresh 1.5 volt battery is about 1.6 volt (1600 mV). Emerson.com...

  • Page 59: Simulate Ph Input

    Reference Manual Troubleshooting 00809-0200-3412 October 2023 10.9  Simulate pH input To simulate a pH measurement, connect a standard millivolt source to the transmitter. If the transmitter is working properly, it will accurately measure the input voltage and convert it to pH. Procedure 1.

  • Page 60: Simulating Inputs - Temperature

    To check the accuracy of the temperature measurement, set the resistor simulating the RTD to the values indicated in Table 10-3 and note the temperature readings. The measured temperature might not agree with the value in Table 10-3. During sensor Emerson.com...
  • Page 61 Reference Manual Troubleshooting 00809-0200-3412 October 2023 calibration, an offset might have been applied to make the measured temperature agree with a standard thermometer. The offset is also applied to the simulated resistance. The transmitter is measuring temperature correctly if the difference between measured temperatures equals the difference between the values in the table to within ±0.1 °C.
  • Page 62 Emerson Terms and Conditions of Sale are available upon request. The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount is a mark of one of the Emerson family of companies. All other marks are the property of their respective owners.

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