Ametek Dycor CG1000-RTP User Manual Download

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Installation & Start-Up

3-1

INSTALLATION

This chapter shows you how to install your CG1000-RTP oxygen analyzer.
It includes the following:

•

Inspect Shipping Contents

•

Mechanical Installation

- Sample gas requirements

- Sample gas set-up

- Calibration gas set-up

- PPM measurement suggestions

•

Electrical Installation

- Current output connections

- Alarm contact connections

- RS-232 communications

- Select 115/230 Volt operation

•

Start-Up and User Interface

There are no operator-serviceable components inside the CG1000-
RTP. Never open the analyzer cover. Refer servicing to qualified
personnel.

Remove any packing material from the sensor and control unit. Check
for damage. If any damage is found, notify the shipper.

NOTE



Summary of Contents for Dycor CG1000-RTP

Page 1: ...Dycor CG1000 RTP User Manual Thermox 150 Freeport Road Pittsburgh PA 15238 PN 90355VE Rev N...

Page 2: ...Corporate Boulevard Newark Delaware 19702 USA Phone 302 456 4400 Main 800 537 6044 Service 800 222 6789 Ordering Fax 302 456 4444 USA Texas AMETEK Process Instruments 9750 Whithorn Drive Houston Texas...

Page 3: ...Contact Connections 3 8 RS 232 Communications Connections 3 9 Select 115 230 Volt Operation 3 9 Start up and User Interface 3 10 System Start Up 3 11 Password Restrictions 3 11 Auto Ranging Feature 3...

Page 4: ...vs Zero Gas 5 2 Aborting a Calibration 5 2 Initiate Cal 5 3 Initiate Verify 5 5 Cal Verify Data 5 7 Cal Gas Value 5 9 Configure Verify 5 10 Set Clock 5 11 Set Time and Date 5 11 Recovery Duration 5 1...

Page 5: ...essage Format A 2 General Serial Communication Commands A 3 Development Serial Communication Commands A 4 Command List A 5 Responses A 6 Variable Table A 7 APPENDIX B Menu Option Charts Setup Key Menu...

Page 6: ...Electrical Safety Up to 5 kV may be present in the analyzer housings Always shut down power source s before performing maintenance or troubleshooting Only a qualified electrician should make electrica...

Page 7: ...d to conserve our natural resources AMETEK recommends that you arrange to recycle this product when it reaches its end of life Waste Electrical and Electronic Equipment WEEE should never be disposed o...

Page 8: ...may not provide sufficient protection depending on the electronic environment Connecting one shield ground via a 0 1 microfarad ceramic capacitor is a technique allowing high frequency shield bonding...

Page 9: ...Switched Off or the Area is Known to be Non Hazardous Risque d explosion Avant de d connecter l quipement coupez le cou rant o vous assurez que l emplacement est design non dangereux All input and ou...

Page 10: ...l Strasse 16 D 40670 Meerbusch Germany Phone 49 21 59 91 36 0 Fax 49 21 59 91 36 39 declares that the product Product Name CG1000 RTP Oxygen Analyzer complies with the requirements of EMC Directive 89...

Page 11: ...ation accompanying the equipment being returned declaring that the goods being returned for repair are American goods the name of the firm who purchased the goods and the shipment date The warranty sh...

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Page 13: ...s of the Sensor The CG1000 analyzer consists of the following basic systems The Plumbing All inlet and outlet tubing cell housing Also includes the calibration gas inlet and aspirator assembly with th...

Page 14: ...the cell a potentiometric voltage is produced See Figure 1 1 The magnitude of this voltage is a function of the ratio of the two oxygen partial pressures If the oxygen partial pressure of one gas is k...

Page 15: ...dicate less oxygen than is actually in the gas Hydrocarbons When hydrocarbons are present in the gas sample a combustion process occurs when this gas sample is exposed to the high temperature of the z...

Page 16: ...e sensor cabinet turn the power off The heater has exposed windings and a short to the plumb ing will blow the fuse and could damage the furnace or thermocouple Do not handle the cell excessively Do n...

Page 17: ...by the factory to provide this information when receiving service Cell millivolts Thermocouple millivolts Cell temperature See the Display section in Chapter 4 for help on how to display this informat...

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Page 19: ...Altitude 2000 meters Power Requirements 115 VAC 60 Hz 150 VA 230 VAC 50 Hz 150 VA Inlet Pressure Limit 3 PSIG Calibration Gas Requirements Use calibration gases 150 sccm limit is 125 to 200 sccm Zero...

Page 20: ...e or verify Set relays to ener gize or de energize on alarm Contact Rating 0 5A 30V 10VA max noninductive load AC or DC Diagnostics Watchdog timer and service alarms System test for A D RAM EEPROM and...

Page 21: ...p PPM measurement suggestions Electrical Installation Current output connections Alarm contact connections RS 232 communications Select 115 230 Volt operation Start Up and User Interface There are no...

Page 22: ...aintain accurate readings To detect when the flow exceeds these limits Alarm 3 can be programmed to alarm on both the high and low flow rate Figure 3 1 shows the sample inlet and outlet ports on the C...

Page 23: ...2 The outlet pressure should not exceed 3 PSIG 207 mil libar 5 Use the Setup Display key on the analyzer front panel to select flow rate for one of the display lines Figure 3 2 Sample Gas Set Up NOTE...

Page 24: ...e stainless steel tubing that is free of oil and dirt to deliver your calibration gases this prevents contamination that could affect proper calibration O2 Range Calibration Gases Span Gas From 1 0 to...

Page 25: ...ystem and influencing calibration gases 4 Temporarily connect a mechanical flow meter to the end of the 9 length of tubing 5 Use the Setup Display key on the analyzer front panel and select Flow Rate...

Page 26: ...gs Quick Response To get the quickest response from your CG1000 RTP analyzer use as small a sample tube diameter as possible The smaller the inside di ameter of the sample tubing the better the respon...

Page 27: ...e CG1000 RTP Figure 3 5 Figure 3 5 J7 and J8 pinouts rear of analyzer IOUT1 IOUT1 IOUT2 IOUT2 Pin 3 Pin 4 Pin 1 Pin 2 These current outputs are referenced as Current Outputs 1 and 2 in soft ware NOTE...

Page 28: ...to power the current outputs use the following formula VEXTmin 02 amps RLoad Rwires 4 volts VEXTmin minimum external voltage required to power current output circuit RLoad load resistance of the curr...

Page 29: ...onnect the AC line power cord from the analyzer Open the top cover of the power entry module using a small blade screwdriver Select the voltage by rotating the fuse holder so the desired voltage align...

Page 30: ...our system for operations and also provides an introduction on how to use the software and keypad keys The following topics are included System Start up Password Restrictions Front Panel Display Auto...

Page 31: ...s a password restriction you must enter the password before you can access menu functions that can change system settings Display You can define which information to place on the first three lines of...

Page 32: ...lect the Display option from the Setup key then select Display Line 1 the current choice to appear on Display Line 1 will appear with the asterisk in front of it for example oxygen If all menu options...

Page 33: ...n you select a menu you can press Help to get a description of the function of any of the menu options within that menu Press Help again to exit on line help and return to the menu options or press Ca...

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Page 35: ...AMETEK Dycor and a service password will be provided so you can access the Pass word option and enter a new system password 1 From the Setup key menu select Passwords Enter new password 2 Enter a four...

Page 36: ...type of calibration unless specifically instructed to do so Carrier Gas Define which carrier gas is used to deliver your calibration gases This option also calibrates your flow sensor Communications...

Page 37: ...n To enter text use the Up and Down Arrow keys on the keypad to scroll through the ASCII text characters Once the letter you want appears press the Right Arrow Key to move to the next position You can...

Page 38: ...calibration This is auto matically done during system start up Test RAM Checks the functionality of the control unit s inter nal Random Access Memory RAM Test Keyboard Tests that each key is functioni...

Page 39: ...xygen cell when your system fails a regular calibration due to a deteriorating cell Regular calibration isn t working Check to see if your calibration gas values match the values written on the gas cy...

Page 40: ...ress Define the physical address for the control unit between 0 and 255 on a network so the host computer can identify the control unit if using network communications Enable Serial Temporarily disabl...

Page 41: ...et port on the back of the analyzer 3 From the Setup key menu select Carrier Gas 4 Select the Cal Flow Sensor menu option Flow Set x sccm 5 Enter the flow rate for gases entering the sensor then press...

Page 42: ...0 mA Set Track Hold Define information sent to analog output port during a calibration Decide whether to hold the output at the last process reading taken before that start of calibration OR track the...

Page 43: ...ill represent You can also choose to set a reverse analog output range so for example 0 mA can correspond to the high end of the oxygen range and 20 mA can correspond to the low end of the oxygen rang...

Page 44: ...r hold the last process reading or track calibration readings Separate decisions can be made for verify and calibrate operations For example you can elect to hold the last process reading during verif...

Page 45: ...t Mode Option Define either a 0 to 20 or 4 to 20 mA analog output range for the selected analog output port This output is dependent on both the range of readings you define see the Set Current Range...

Page 46: ...u should enter 01 to enter 1 07 to enter 7 70 for 70 etc The default value is 100 no filtering Select Function Option Select what type of information the analog output port should track Choic es are O...

Page 47: ...tion you make here applies to all alarms except the Watchdog and Service alarms which always de ener gize on alarm Select Function Define whether Alarm 3 activates based on oxygen flow or start of cal...

Page 48: ...em alarm condition Alarm 4 Not selectable O2 only High O2 alarm Low O2 alarm Disabled during calibration cycle and during system alarm condition Alarm Set Points Set alarm limits Define whether these...

Page 49: ...want to enter the Alarm 3 set point using a percent or PPM range If Alarm 3 is tracking flow set the high and low flow limits 3 You will be prompted to define the Alarm 3 set point value Alarm 3 xx N...

Page 50: ...ess Cancel to exit this menu option To create two high oxygen alarms define both Alarm 3 and Alarm 4 as high oxygen alarms Relay Configure All Series CG1000 RTP relays are Form A normally open contact...

Page 51: ...ing the select function From the Alarm menu choose Select Function Select Alarm 3 O2 Flow Alarm 3 In Cal or Alarm 3 In Verify depending on whether Alarm 3 should be associated with oxygen levels flow...

Page 52: ...e Setup key for a long enough time will in turn cause a watchdog which will indicate as a beep after the system restarts upon release of the reset keys Exception Log The exception log provides a histo...

Page 53: ...nown values of calibration gas cylinders Configure Verify Enter verify gas value Enter acceptable verify range Set Clock Set the current date and time Set calibration recovery times All oxygen alarms...

Page 54: ...o check that the instrument is running within required tolerances Calibration During a calibration operation software algorithms adjust the dif ference between the current readings and the known calib...

Page 55: ...n plumbing Continue Cal Abort Calibration You are prompted to run the O2 span gas Inject Span Verify Gas ENTER to continue CANCEL to Abort 3 Set the 3 way valve on the back of the analyzer to the CAL...

Page 56: ...7 You are prompted to apply the O2 zero gas Inject Zero Gas ENTER to Continue CANCEL to Abort 8 Set the 3 way valve that delivers the calibration gases to the ZERO gas position 9 Press ENTER once you...

Page 57: ...r calibration values or set up calibration plumbing Continue Verify Abort Cal Verify 3 You are prompted to apply the verify gas to the calibration inlet port on the back of the analyzer tubing must be...

Page 58: ...gas cylinder for the verify gas you applied to the calibration inlet port on the back of the analyzer If you specified a recovery time the system will display the recovery time remaining Recovery xx...

Page 59: ...tion gas value and the calibration gas values read by the system Both the latest calibration and verification data will be stored in memory Setting Up Cal Verify Data Option 1 From the Calibrate Key m...

Page 60: ...onfigure Verify option from the Calibrate Key menu Press ENTER The time when the verification was completed appears on the display End time hr mn End date mm dd yr If the date or time has not been set...

Page 61: ...ing a value 4 Choose whether you want to enter the zero gas value using a percent or PPM scale If you specified a ppm gas as the span gas in Step 2 the zero gas must also be a ppm gas In this case you...

Page 62: ...rrent zero gas value unchanged press ENTER without entering a value 4 Enter the acceptable verify range For example if you enter a verify gas range of 1 and the verify gas value is 10 then the accepta...

Page 63: ...s YY XX Enter new time HR Mn 3 Enter the new time and press ENTER As you type the new time it overwrites the Hr Mn text If the current time is correct press the ENTER key without changing the value En...

Page 64: ...h calibrations and verifications 1 From the Calibrate key menu select Set Clock 2 Select Recovery Duration from the Set Clock menu option Cal Recovery xx yy Enter new time Mn Sc 3 Enter the recovery t...

Page 65: ...System and Error Messages System and error messages appear on the fourth line of the display at three second intervals until the condition is corrected or has ended If there is more than one message t...

Page 66: ...libration will determine the constants needed for the Nernst equation If you see this message select the Calibrate Key and perform a calibration This message will not clear from the dis play by removi...

Page 67: ...d pressure sensor Failed cell primary calibration should be run at this time Leak or plug in plumbing Cell lead wires polarity reversed Flow sensor not calibrated Wrong carrier gas selected Memory is...

Page 68: ...of thermocouple wires is incorrect Display module failure Backplane board failure If this message is soon followed by a Thermocouple Failure message see that message for troubleshooting instruc tions...

Page 69: ...leading to pins TC and TC on the backplane board To check the continuity of the thermocouple measure resistance across pins TC and TC on the backplane board The resistance should be less than 5 Ohms...

Page 70: ...lead no polarity Calibration Checks Calibration Setup Checks Check that the correct calibration gas values have been entered into the control unit Select the Cal Gas Value menu option from the Calibra...

Page 71: ...is not heating Disconnect power and check the furnace resistance If no voltage is present at terminals TB1 Pins 1 and 2 on the back plane board check for the DC furnace drive signal at the top of resi...

Page 72: ...teel prevents any prob lems that might occur with plastic melting the nozzle on hot sensor components Connect a vacuum pump to the outlet of the analyzer vacuum should not exceed 5 psig and apply a lo...

Page 73: ...Replacement Furnace Replacement Transformer Replacement Backplane Board Replacement Display Keypad Module Replacement Unplug the power cord from the power source and the analyzer when servicing system...

Page 74: ...screws on the sides bottom sides of the analyzer Lift off the top cover 4 Loosen and remove the two Swagelok nuts on the cell tee assembly Always use a backup wrench when working on sensor plumbing 5...

Page 75: ...you push in the cell You will need to apply extra pressure until the cell touches the bottom of the cell tee Once the cell bottoms out push the O ring back against the T fitting The O ring must be pos...

Page 76: ...ing elbow to the cell tee Hand tighten the Swagelok nut then use a wrench to tighten an additional one quarter turn Always use a backup wrench when working on sensor plumb ing 7 Reinstall the inlet an...

Page 77: ...ds and distorting sensor plumbing Removing the Old Furnace Figure 7 4 Furnace assembly 1 Remove the cell mount nut see the Cell Replacement section for help The cell and inlet tube can be removed as a...

Page 78: ...Retrieve an anti seize and lubricating compound for example NEVER SEEZ catalog number NSB 4 from Bostik Chemical Group Apply the anti seize compound to the inside diameter of the Swagelok body Retrie...

Page 79: ...fur nace by reversing the actions taken in Step 5 of removing the furnace 6 Reconnect the thermocouple wires to TB2 TC and TC on the back plane board Yellow wire TC Red wire TC 7 Reconnect the furnac...

Page 80: ...ne board 3 Unplug J3 connector from the transformer 4 Unplug J7 connector from the backplane board You will need to do this to make room to remove the transformer 5 Remove the four screws the four sho...

Page 81: ...and T C and TB1 AC AC 5 Remove J3 J4 J5 J6 and J7 connections 6 Remove the front panel 7 Remove the power supply and display modules see the applicable section in this appendix for help 8 Remove the t...

Page 82: ...nel Push the front panel to the right until it unlatches from the side tab then push to the left until it unlatches from the other side tab 5 Pull on the power supply keypad module PN 90253VE and remo...

Page 83: ...aud rate of the host device Baud rates are user programmable See the Communication section in the Setup key chapter for help on defining control unit baud rates The communication protocol is a basic m...

Page 84: ...de Address section in the Setup Key chapter for help on specify ing node addresses for controllers The maximum number of controllers that can be connected on the network is 32 The Command Letter is fr...

Page 85: ...s where applicable Example Request oxygen with the following string 00F080E Returned string A20 9 O2D4 Write Number H Set a value at the CG1000 RTP The data section of this command is a two digit hex...

Page 86: ...eady to communicate Data Format J Check how data is output through the serial link For each variable that is accessible through the Read Number and Write Number commands a string is returned that desc...

Page 87: ...ion provides the command letters you can use Command Letter Description A Echo B Bad Command C Acknowledge F Read Number G Calibrate H Write Number J Data Format M Read Date and time N Set Date and Ti...

Page 88: ...rs Checksum 2 hex ASCII characters End Character Examples A Simple acknowledge AFF0050 Acknowledge with data Failure All failure responses start with a N followed by a two hex digit failure code and a...

Page 89: ...bration Required 6 Excessive cal Error 5 Memory is corrupted 4 Primary calibration 3 span gas Range Error 2 Zero gas Range Error 1 cell is over Temp 0 Temp Rise Failure Byte 3 bit 7 Available 6 Availa...

Page 90: ...ure use 6 0 4 20 ma 1 0 20 ma 5 0 Holds during verify 1 Tracks during verify 4 0 Holds during cal 1 Tracks during cal Analog output 1 3 Future use 2 0 4 20 ma 1 0 20 ma 1 0 Holds during verify 1 Track...

Page 91: ...command 6c for 1F Alarm 4 sP FloAT in ppm see command 6d for 29 Recovery Time HEX XXXX where 0200 means 2 00 2A span gas value FloAT 2B Zero gas value FloAT 4d Pressure FloAT 4E operation Temp FloAT 5...

Page 92: ...use 3 oxygen low Alarm 2 2 oxygen High Alarm 2 1 oxygen low Alarm 1 0 oxygen High Alarm 1 69 oxygen FloAT oxygen value in ppm 6A Alarm3_flg HEX 1 Alarm 3 is in ppm 0 Alarm 3 is in 6B Alarm4_flg HEX 1...

Page 93: ...e Millivolts Cell Temperature User Text Turn Off Password Enter password Set Pressure Set Process Pressure System Tests Various System Serial Serial Manufacturing Thermal Calibrate Perform a thermal c...

Page 94: ...as acceptable range Set Clock Set time date Define recovery time duration after a calibration Figure B 2 Calibrate Key menu Alarm Key Menu Alarm Key Menu Menu Options Alarm Set Points Alarm 3 Value Al...

Page 95: ...ld output at last process reading during calibration Track calibration readings during calibration Set Current Mode 4 to 20 mA 0 to 20 mA Output Filtering Enter output filter value 100 no filtering 1...

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