Instruction/ maintenance manual of the product 51-DO-04 Emerson
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Model DO-03/04 Dissolved Oxygen Measurement System with Air Blast Cleaner Instruction Manual 51-DO-03/04/rev .C October 2004.
ESSENTIAL INSTRUCTIONS READ THIS P AGE BEFORE PROCEEDING! Rosemount Analytical designs, manufactures, and tests its products to meet many national and international standards.
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MODEL DO-03/04 T ABLE OF CONTENTS MODEL DO-03/04 MEASURING SYSTEM T ABLE OF CONTENTS Section Title Page 1.0 SPECIFICA TIONS ................................................................................................... 1 1.1 Features and Applications .
9.0 MAINTENANCE ...................................................................................................... 50 9.1 Analyzer (Model 54eA-01) ....................................................................................... 50 9.2 Oxygen Sensor (Model 499ADO-54) .
iii MODEL DO-03/04 T ABLE OF CONTENTS LIST OF FIGURES Section Title Page 1-1 Suggested Arrangement of Handrail Mounting Assembly , Maintenance Clamp, .... Air Compressor Enclosure, and 54eA Analyzer ....................................................
1 MODEL DO-03/04 SECTION 1.0 SPECIFICA TIONS SECTION 1.0 SPECIFICA TIONS • COMPLETE SYSTEM INCLUDES sensor , analyzer , sensor washer head, mounting hard- ware, and air compressor. • AIR BLAST CLEANER system can keep DO sensors funtioning up to 3 months or longer.
MODEL DO-03/04 SECTION 1.0 SPECIFICA TIONS 2 SPECIFICA TIONS - 499ADO-54 SENSOR Range: 0 to 20 ppm (mg/L) Wetted p art s: Noryl 1 V iton 2 EPDM, T eflon 3 , silicone Cathode: Gold (not normally wetted) Accuracy: ±0.2 ppm at 25°C Repeat ability: ±0.
MODEL DO-03/04 SECTION 1.0 SPECIFICA TIONS 3 SPECIFICA TIONS - COMPRESSOR FOR AIR BLAST CLEANER SYSTEM Enclosure: Fiberglass reinforced polyester with poly- ester cover , NEMA 4x (IP65). 1 1.9 x 1 1.9 x 6.9 in (302 x 302 x 175 mm). Compressor: Oil-less, non-lubricating piston and cylinder .
MODEL DO-03/04 SECTION 1.0 SPECIFICA TIONS 4 FIGURE 1-2. Analyzer dimensions WHEN INCH AND METRIC DIMS ARE GIVEN MILLIMETER INCH FIGURE 1-1. Suggested arrangement of handrail mounting assembly , maint.
MODEL DO-03/04 SECTION 1.0 SPECIFICA TIONS FIGURE 1-3. Enclosure dimensions WHEN INCH AND METRIC DIMS ARE GIVEN INCH MILLIMETER FIGURE 1-4. St andard sensor with integral cable FIGURE 1-5.
6 MODEL DO-03/04 SECTION 1.0 SPECIFICA TIONS ORDERING INFORMA TION The Model DO -03/04 is a complete system for the determination of oxygen in wastewater aeration basins. It consists of a 54eA analyzer , a 499ADO-54 oxygen sensor , an air blast washer head with air compressor and hose, and a handrail mounting bracket.
7 MODEL DO-03/04 SECTION 2.0 INST ALLA TION SECTION 2.0 INST ALLA TION 2.1 UNP ACKING AND INSPECTION Inspect the shipping container . If it is damaged, contact the shipper immediately for instructions. If there is no apparent damage, unp ack the container .
2.2.2 Inst alling the analyzer When used in Model DO-03/04, the 54eA analyzer is intend- ed to be mounted on the basin handrail. See Figures 2-1 and 2-2. 2.2.3 Inst alling the air compressor enclosure The air compressor is in a NEMA 4X fiberglass enclosure.
9 MODEL DO-03/04 SECTION 2.0 INST ALLA TION 2.2.6 Inst alling the sensor in the washer head assembly 1. Remove the sensor from its box. Remove the plastic protective cap from the end of the sensor . Save the cap. 2. Replace the knurled cap provided with the sensor with the smooth cap (PN 33521-01).
10 MODEL DO-03/04 SECTION 2.0 INST ALLA TION FIGURE 2-3. Att aching the air compressor enclosure to the handrail FIGURE 2-4. Assembling and att aching the handrail mounting assembly . The spring pin (not shown) shipped with the handrail mounting assembly is not used.
MODEL DO-03/04 SECTION 2.0 INST ALLA TION FIGURE 2-5. Inst alling the sensor in the washer head assembly 11.
12 MODEL DO-03/04 SECTION 3.0 WIRING SECTION 3.0 WIRING 3.1 GENERAL W ARNING Electrical installation must conform to the National Electrical Code, all st ate and local codes, and all plant codes and standards for electrical equipment. Electrical inst allation and wiring must be done by qualified personnel.
13 MODEL DO-03/04 SECTION 3.0 WIRING FIGURE 3-1. Power Input, Relay , and Output Wiring for 54eA analyzer DWG . NO. REV . 454EPH02 D.
14 MODEL DO-03/04 SECTION 3.0 WIRING FIGURE 3-2. Model DO-03 — Wiring Air Blast Compressor to Model 54eA Analyzer 1 15 V ac.
MODEL DO-03/04 SECTION 3.0 WIRING FIGURE 3-3. Model DO-04 — Wiring Air Blast Compressor to Model 54eA Analyzer 230 V ac 15.
16 MODEL DO-03/04 SECTION 3.0 WIRING FIGURE 3-4. Wiring Label 3.3 SENSOR WIRING 3.3.1 General The wiring label, which is shown in Figure 3-4, is a general purpose label. It has wiring infor- mation concerning other sensors, for example, contacting conductivity and pH, that can be used with the 54eA instrument platform.
MODEL DO-03/04 SECTION 4.0 DISPLA Y AND OPERA TION SECTION 4.0 DISPLA Y AND OPERA TION 4.1 DISPLA Y Figure 4-1 shows the main display . 4.2 KEY FUNCTIONS AND CONTROL The keys labeled F1, F2, F3, and F4 are multi-function. The function appears in the main display just above the key .
18 MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION SECTION 5.0 SOFTW ARE CONFIGURA TION Figure 5-1 is an outline of the menu structure. FIGURE 5-1.
MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION Program Calibrate (see previous page) Diagnostic V ariable (see previous page) Main Menu Alarms 1, 2, and 3 setpoints 4 mA or 0 mA 20 mA Present out.
20 MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION FIGURE 5-1. Menu T ree for the 54eA Analyzer (continued) Display (see page 17) Outputs (see page 17) Alarms (see page 17) Program Calibrate (see .
MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION T ABLE 5-1. Program Settings List Continued on the following page ITEM CHOICES F ACTOR Y SETTINGS SETPOINTS A. Alarms (Section 5.1) 1. Alarm 1 (low action) a. if oxygen (ppm) -99 to 99 ppm 0 ppm b. if oxygen (% saturation) 0 to 200% 0 % c.
22 Continued on the following page MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION ITEM CHOICES F ACTOR Y SETTINGS CONFIGURE B Output s (Section 5.5) 1. Output 1 a. Measurement Oxygen or temperature Oxygen b. Control Normal Normal 2. Output 1 Setup a.
MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION ITEM CHOICES F ACTOR Y SETTINGS CONFIGURE (continued) D.T emperature compensation (Section 5.7) 1. T emperature compensation Auto or manual Auto 2. Manual temperature -15 to 130°C 25°C E. Noise Reduction (section 5.
24 5.1 CHANGING ALARM SETPOINTS 2. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 3. Press Enter (F4). 4. Move the cursor to the desired alarm and press Enter (F4). 5. A screen like the one shown will appear .
MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.2 RANGING THE OUTPUTS 2. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 3. Move the cursor to "Output setpoint s" and press Enter (F4).
26 MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.3 TESTING OUTPUTS AND ALARMS 2. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 3. Move the cursor to "Simulated test s" and press Enter (F4).
Output setpoint s Simulated test s Configure Exit Enter MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.4 CHOOSING DISPLA Y OPTIONS 4. Move the cursor to "Configure" and press Enter (F4). 5. With the cursor on "Display", press Enter (F4).
28 MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.4 CHOOSING DISPLA Y OPTIONS (CONTINUED) 7. Set the remainder of the display parameters. Use the and keys to choose the desired parameter . Then press Edit (F4). Use the key to move the cursor to the desired selection.
MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.5 CHANGING OUTPUT P ARAMETERS 2. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 3. Move the cursor to "Configure" and press Enter (F4).
30 MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.5 CHANGING OUTPUT P ARAMETERS (continued) 7. Output setup for normal output s: a. Move the cursor to the desired output setup and press Enter (F4). b. Use the and arrow keys to move the cursor to the desired parameter .
MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.6 CHANGING ALARM P ARAMETERS 2. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 3. Move the cursor to "Configure" and press Enter (F4). 4.
32 MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.6 CHANGING ALARM P ARAMETERS (continued) c. T o change the activation method, press Edit (F4). Use the key to scroll through the choices, "Process" or "T emperature". "Process" means dissolved oxygen.
Feed limit : Disable T imeout: 3600 sec Exit Edit 1.000 ppm 26.2°C 12.0mA Feed limit alarm 1 MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.6 CHANGING ALARM P ARAMETERS (continued) 9. Alarm 4 setup: Alarm 4 is a dedicated fault alarm. When a fault condition exists, the red LED on the front display will light.
34 MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.6 CHANGING ALARM P ARAMETERS (continued) 1 1. Interval timer setup: Alarm 1, 2, or 3 can be used as an interval timer . The selected relay will open and close at time intervals programmed by the user .
T emp comp : Auto T emp unit s: °C Exit Edit T emp comp: Manual T emp unit s: °C T emperature : 25.0°C Exit Edit MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.7 TEMPERA TURE COMPENSA TION AND TEMPERA TURE UNITS 1. Refer to Section 6.1 for a discussion of the ways in which temperature af fects dissolved oxygen measurement.
36 Noise rejection : 60 Hz Exit Edit MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.8 NOISE REDUCTION 1. For maximum noise reduction the frequency of the ac power must be entered into the analyzer . T emperature Noise rejection Main sensor cal Exit Enter 2.
Bar meas : Auto Bar unit s: mm Hg Exit Edit MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.9 BAROMETRIC PRESSURE 1. Barometric pressure is used during air calibration. Noise rejection Barometric pressure Main sensor cal Exit Enter 2. Press any key to enter the main menu.
38 S tabilize : 0.050 ppm S tabilize time: 10 sec Exit Edit S tabilize: 0.050 ppm S tabilize time: 10 sec Salinity : 0.0 o /oo Exit Edit MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.10 MAIN SENSOR CALIBRA TION P ARAMETERS 1. Main sensor refers to the dissolved oxygen sensor .
MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.1 1 SECURITY 1. The analyzer can be programmed to require a password for access to menus. There are three levels: Level 1: A level 1 user can 1. Zero and calibrate the oxygen sensor 2. Calibrate the barometric pressure sensor 3.
40 MODEL DO-03/04 SECTION 5.0 SOFTW ARE CONFIGURA TION 5.12 ANAL YZER MODE PRIORITY The Model 54eA analyzer can function in different modes depending on how it is configured, what process condi- tions exist, and actions an operator may have made.
41 MODEL DO-03/04 SECTION 6.0 CALIBRA TION - TEMPERA TURE SECTION 6.0 CALIBRA TION - TEMPERA TURE 6.1 INTRODUCTION The Model 499ADO sensor is a membrane-covered amperometric sensor . As the sensor operates, oxygen dif fus- es through the membrane and is consumed at an electrode immediately behind the membrane.
42 6.2 TEMPERA TURE CALIBRA TION MODEL DO-03/04 SECTION 6.0 CALIBRA TION - TEMPERA TURE 2. From the main display , press any key . With the cursor on “Calibrate,” press Enter (F4). NOTE If Hold was enabled in Section 5.5, the hold screen will appear .
MODEL DO-03/04 SECTION 7.0 CALIBRA TION - DISSOL VED OXYGEN SECTION 7.0 CALIBRA TION - DISSOL VED OXYGEN 7.1 INTRODUCTION As Figure 7-1 shows, oxygen sensors generate a current directly proportional to the concentration of dissolved oxygen in the sample.
44 1. Place the sensor in a fresh solution of 5% sodium sulfite (Na 2 SO 3 ) in water . Be sure air bubbles are not trapped against the membrane. The current will drop rapidly at first and then gradually reach a st able zero value. T o monitor the sensor current, go to the main display .
1. Remove the sensor from the process liquid. Use a soft tissue and a stream of water from a wash bottle to clean the membrane. Blot dry . The membrane must be dry during air calibration. 2. Pour some water in a beaker and suspend the sensor with the membrane about 0.
46 MODEL DO-03/04 SECTION 7.0 CALIBRA TION - DISSOL VED OXYGEN 9. During calibration, the analyzer stores the measured current and calcu- lates the sensitivity . Sensitivity is the sensor current in nA divided by the saturation concentration of oxygen in ppm.
The analyzer and sensor can be calibrated against a standard instrument. For oxygen sensors inst alled in aera- tion basins in waste treatment plants, calibration against a second instrument is of ten preferred. For an accurate calibration be sure that… 1.
48 1. If the barometric pressure measured by the analyzer does not agree with the local barometric pressure, cali- brate the pressure sensor . A pressure error of 3 mm Hg introduces an error of about 0.5% in the final meas- urement. When calibrating the pressure reading, be sure to use the actual barometric pressure.
MODEL DO-03/04 SECTION 8.0 CALIBRA TION - CURRENT OUTPUTS SECTION 8.0 CALIBRA TION - CURRENT OUTPUTS 8.1 INTRODUCTION Although the analyzer outputs are calibrated at the factory , they can be trimmed in the field to match the reading from a standard current meter .
50 MODEL DO-03/04 SECTION 9.0 MAINTENANCE SECTION 9.0 MAINTENANCE 9.1 ANAL YZER (MODEL 54eA-01) The Model 54eA-01 analyzer provided with the Model DO-03/04 system requires little routine maintenance. Clean the analyzer enclosure and front panel by wiping with a clean sof t cloth dampened with water .
MODEL DO-03/04 SECTION 9.0 MAINTENANCE T o reassemble the sensor and air blast cleaner… 1. Inspect the sensor O-ring. If it is cracked or cut, replace it. Clean the O-ring and slide it over the end of the sensor until it rests against the lower edge of the bottom facing threads.
52 MODEL DO-03/04 SECTION 9.0 MAINTENANCE 9.3 AIR COMPRESSOR (PN 9380088 1 15V ac or PN 9380089 220 V ac) The air compressor has no user-serviceable part s. It does not require lubrication. Fuse sizes are shown in the table. The fuse is located below the T -shaped plastic cover next to the air compressor .
MODEL DO-03/04 SECTION 9.0 MAINTENANCE FIGURE 9-2. Replacement Part s 9.4 AIR BLAST SENSOR W ASHER The air blast sensor washer needs little routine maintenance. Replace the two large O-rings on the base of the washer head and the sensor sealing O-ring if they become cut or dirty or if there is evidence of water leaking into the washer head.
54 MODEL DO-03/04 SECTION 10.0 TROUBLESHOOTING SECTION 10.0 TROUBLESHOOTING 10.1 OVERVIEW The 54eA analyzer continuously monitors itself and the sensor for faults. When the analyzer detects a fault in the oxygen sensor or in the instrument itself it displays a fault message .
MODEL DO-03/04 SECTION 10.0 TROUBLESHOOTING 10.2.1 High input current Excessive sensor current implies that the oxygen sensor is miswired or the sensor has failed. V erify that wiring is correct, including connections through a junction box. See Section 3.
56 MODEL DO-03/04 SECTION 10.0 TROUBLESHOOTING 10.3 TROUBLESHOOTING WHEN NO F AUL T MESSAGE IS SHOWING - TEMPERA TURE 10.3.1 T emperature measured by st andard was more than 1°C different from analyzer .
MODEL DO-03/04 SECTION 10.0 TROUBLESHOOTING 10.4.2 Zero reading Is unst able. A. Is the sensor properly wired to the analyzer? See Section 3.3. V erify that all wiring connections are tight. B. Readings are often erratic when a new or rebuilt sensor is first placed in service.
58 MODEL DO-03/04 SECTION 10.0 TROUBLESHOOTING 10.4.6 Process readings are erratic. A. Readings are often erratic when a new sensor or a rebuilt sensor is first placed in service. The current usual- ly stabilizes af ter a few hours. B. Is the sample flow within the recommended range? High sample flow may cause erratic readings.
MODEL DO-03/04 SECTION 10.0 TROUBLESHOOTING 10.5 TROUBLESHOOTING NOT RELA TED TO MEASUREMENT PROBLEMS Problem Action Display segments missing Replace display board Alarm relays are chattering 1. Check alarm setpoints. 2. Increase hysteresis time delay settings (see Section 5.
60 MODEL DO-03/04 SECTION 10.0 TROUBLESHOOTING 10.7 SIMULA TING TEMPERA TURE 10.7.1 General. The 54eA analyzer accepts a Pt100 R TD. The Pt100 R TD is in a three-wire configuration. See Figure 10-2. 10.7.2 Simulating temperature T o simulate the temperature input, wire a decade box to the analyzer or junction box as shown in Figure 10-3.
MODEL DO-03/04 SECTION 1 1.0 RETURN OF MA TERIAL SECTION 1 1.0 RETURN OF MA TERIAL 1 1.1 GENERAL. T o expedite the repair and return of instruments, proper communication between the customer and the factory is important. Before returning a product for rep air , call 1-949-757-8500 for a R e t urn Materials Authorization (RMA) number .
FROM: RETURN BILL TO: _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ ____________________________.
W ARRANTY Seller warrants that the firmware will execute the programming instructions provided by Seller , and that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expira- tion of the applicable warranty period.
Credit Cards for U.S. Purchases Only . The right people, the right answers, right now . ON-LINE ORDERING NOW A V AILABLE ON OUR WEB SITE http://www .raihome.com Specifications subject to change without notice. Emerson Process Management Liquid Division 2400 Barranca Parkway Irvine, CA 92606 USA T el: (949) 757-8500 Fax: (949) 474-7250 http://www .
An important point after buying a device Emerson 51-DO-04 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Emerson 51-DO-04 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Emerson 51-DO-04 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Emerson 51-DO-04 you will learn all the available features of the product, as well as information on its operation. The information that you get Emerson 51-DO-04 will certainly help you make a decision on the purchase.
If you already are a holder of Emerson 51-DO-04, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Emerson 51-DO-04.
However, one of the most important roles played by the user manual is to help in solving problems with Emerson 51-DO-04. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Emerson 51-DO-04 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
