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Dycor CG1100 Oxygen Analyzer

User Manual

PN 90484VE, Rev. J

Process Instruments

150 Freeport Road

Pittsburgh, PA 15238

Summary of Contents for Dycor CG1100 Series

Page 1: ...Dycor CG1100 Oxygen Analyzer User Manual PN 90484VE Rev J Process Instruments 150 Freeport Road Pittsburgh PA 15238...

Page 2: ...0399 CHINA AMETEK Shanghai SPL Room 408 Metro Tower 30 Tian Yao Qiao Road Shanghai 200030 Ph 86 21 6426 8111 Fax 86 21 6426 7054 USA Delaware 455 Corporate Blvd Newark DE 19702 Ph 302 456 4400 Fax 30...

Page 3: ...ort 1 6 CHAPTER 2 Specifications CHAPTER 3 Installation Mechanical Installation 3 3 Analyzer Description 3 4 Sample Gas Flow 3 7 Sample Gas Requirements 3 7 Sample Gas Set Up Connections 3 7 Calibrati...

Page 4: ...n 5 1 CHAPTER 6 Diagnostic Checks and Troubleshooting Diagnostics Checks 6 1 Wiring Checks 6 2 Wiring Problem 6 2 Analog Board Connections 6 2 Ribbon Connectors 6 2 hermocouple Checks 6 3 Calibration...

Page 5: ...v APPENDIX A Communications Protocol Protocol Summary A 1 Addresses A 2 Defined Responses slave to master A 3 Function Codes A 4 Variables A 6...

Page 6: ...rical 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 electrical con...

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

Page 8: ...ground via a 0 1 microfarad ceramic capacitor is a technique allowing high frequency shield bonding while avoiding the AC ground metal connection In the case of shielded cables the drain wire or braid...

Page 9: ...Product Name Model CG1100 Oxygen Analyzer series Model Number s CG1100 GS CG1100 M CG1100 RTP CG1100 CG1101 CG1100 GS RCU conform to the following standards EMC Directive 89 336 EEC EN 61326 1 Radio...

Page 10: ...the documentation 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 Th...

Page 11: ...chieved through the following connections One analog output 4 to 20 mA isolated can be either loop powered or powered by the analyzer or one voltage output Four alarm contacts dry relay contacts One R...

Page 12: ...le compensation intercon nect wiring and the control unit The temperature system keeps the sensing cell at a constant temperature The Oxygen Measuring Cell The sensing element itself is a closed end t...

Page 13: ...e created by the difference in the sample gas and the reference air is carried by cable to the microprocessor control unit where it is linearized to an output signal Because of the high operating temp...

Page 14: ...rnace or thermocouple Do not handle the cell excessively Do not try to clean the cell except by rinsing Do not remove a cell or type K thermocouple that you may want to use again when the inside of th...

Page 15: ...nit at the inductive loads Be sure to place the transient suppressor as close to the load as possible Examples of transient suppressors include MOVs TRANSORBs and RC snubbers AC mains supply wiring sh...

Page 16: ...call AMETEK at 412 828 9040 or your local AMETEK Dycor representative If you need to return equipment you will be asked to provide the follow ing information before obtaining a Return Material Author...

Page 17: ...ailable with 100 250 VAC 47 63 Hz input AMETEK 25446JE When using an external power supply a power connector plug AMETEK 19674JE is required Inlet Pressure Range 600 to 1795 Torr Absolute maximum allo...

Page 18: ...an externally accessible selector switch Baud rate is software selectable to 9600 or 19200 baud Uses CG1100 compatible protocol I O DB 15 connector 2 software configurable alarms for oxygen flow and...

Page 19: ...ons Electrical Installation Wiring Alarm contact connections Output Wiring Status LEDs and Alarms Connection to Line Power There are no operator serviceable components inside the CG1100 Never open the...

Page 20: ...3 2 Dycor CG1100 Oxygen Analyzer Minimum Pressure Drop vs Flow Flow sccm Pressure Torr 0 5 10 15 20 0 50 100 150 200 250 Figure 3 1 Minimum pressure drop vs flow...

Page 21: ...sure In general 20 Torr less than inlet pressure Locate the CG1100 as close to sampling system as possible If running your system at a flow rate other than 100 sccm it will be necessary to recali brat...

Page 22: ...ss from 01 to 32 After setting the switches you must reset the system by cycling the power unplugging the system and plugging it back in to the power source Setting the MSD to 0 position and the LSD t...

Page 23: ...em used to maintain the flow rate set in the configurator software The accuracy of the oxygen analyzer readings are flow dependent Maintaining the same flow rate during calibration ensures the accurac...

Page 24: ...G1100 Oxygen Analyzer Mass Flow Meter Cell Gas IN Gas OUT Figure 3 4A Sample gas flow CG1100 front view GAS IN GAS OUT Mass Flow Meter GAS IN GAS OUT Mass Flow Meter Figure 3 4B Sample gas flow CG1100...

Page 25: ...the outlet of the metering valve to the sample gas inlet on the back panel of the analyzer using 1 8 tubing This connection is labeled Sample Figure 3 3 For the best response time ensure that the sam...

Page 26: ...tor software Calibration Gas Requirements NOTE Use stainless steel tubing that is free of oil and dirt yo deliver your calibration gases this prevents contamination that could affect proper calibratio...

Page 27: ...influencing calibration gases 4 Connect a mechanical flow meter to the end of the 9 length of tubing 5 You can skip this step if using room air as your span gas Set the 3 way valve to the Span Gas po...

Page 28: ...ine can affect PPM oxygen readings Quick Response To get the quickest response from your CG1100 analyzer use 1 8 stain less steel tubing for the sample inlet Also ensure that the length of the sample...

Page 29: ...ures 3 10a and b 3 Insert the RS 485 termination plug into the RS 485 OUT connection if communicating with one analyzer or into the last in a chain 4 Connect the 24 VDC power to the analyzer Wiring Ve...

Page 30: ...00 Oxygen Analyzer 0 5V Board Component side of this board faces the component side of the analog board The 0 5 volt board is plugged into the analog board solder side up Figure 3 8 Analog board for C...

Page 31: ...chassis at each CG1100 If this is not possible e g ground loop tie the shield at the PC or DCS to chassis and remaining shield to earth through a 0 1uf 500v capacitor Analog Digital I O Connector Ext...

Page 32: ...ctor 2 3 4 5 8 2 3 4 5 8 RD TD DTR GND CTS CG1100 Type DB9M PC Type DB9F TD RD GND 2 3 4 5 8 3 2 20 7 5 RD TD DTR GND CTS CG1100 Type DB9M PC Type DB25F TD RD GND Figure 3 10a RS 232 cable connections...

Page 33: ...D B GND 12V Power Supply 9 8 5 4 RX RX TX TX RS 485 CG1100 Type DB9M Converter Part 73858SE OFF ON 2 WIRE 5 4 RX A RX B RS 485 CG1100 Type DB9M Converter Part 73858SE TD A TD B PC RS 232 DB 9 Figure 3...

Page 34: ...port on the front of the CG1100 analyzer Follow the instructions below to connect the serial cable to the RS 232 port 1 Plug the male end of the RS 232 adapter cable into the port labeled RS 232 on th...

Page 35: ...have a watchdog event and the system returns to normal operations then the watchdog alarm will reset The system will retain in memory the last time the watchdog condition occurred The Service alarm is...

Page 36: ...t then the analyzer is configured for a current output 4 20 mA Output Wiring 0 5 Volt Output Wiring IOUT Pin 4 VOUT Pin 1 IOUT Pin 3 VOUT Pin 2 Analog Digital and I O Pinout Reference Description Part...

Page 37: ...of priority with the highest priority alarm having the least number of flashes YELLOW Communication status flashing during communication Alarm Source LED Flashes Cycle Problem Action RAM or EEPROM Fai...

Page 38: ...supply module to the power input connection on the CG1100 2 Align the key and push in the connector 3 Push the outer ring over the connector and rotate clockwise until the ring locks in place The DC p...

Page 39: ...tputs and PC and device communications using CG1100 system configurator software See instructions in this chapter 6 If you are running a cal gas initially check the O2 reading by clicking on the softw...

Page 40: ...Insert the Setup Disk 1 into your floppy disk drive 2 Click RUN from the Windows Start Menu 3 Type the drive letter followed by a colon and a backslash and the word setup Example a setup 4 Follow the...

Page 41: ...on information Save Configuration Saves analyzer internal parameters to a file The Save As dialog box will appear so that you can name the file Restore Configuration Restores analyzer internal paramet...

Page 42: ...up PC communications Port Select the COM port on the computer used to connect to you device Baud Rate Select the baud rate at which data will be transferred Either 9600 or 19200 RS 232 Port Click if d...

Page 43: ...the baud rate at which data will be transferred RS 485 Identifies the analyzer s address and the type of serial com munication cable being used Address Type the network address for the device being co...

Page 44: ...pressure Concentration Define calibration settings Span Enter span gas in percent or PPM Initiate span gas Check O2 reading on the Status tab until O2 reading stabilizes Then click the Calibration ta...

Page 45: ...rm Oxygen Enable oxygen alarm Flow Enable flow alarm High limit Enter high limit value Low limit Enter low limit value Alarm output 2 Disabled Disable alarm Oxygen Enable oxygen alarm Flow Enable flow...

Page 46: ...s Figure 4 6 a b Analog tab on configurator software Analog output selectable for oxygen and flow Disabled Disable analog output Oxygen Enable oxygen analog output Flow Enable flow analog output Full...

Page 47: ...s out when clicked and calibration is in process Calibrate zero Begins calibration for zero gas Button grays out when clicked and calibration is in process Cancel abort Click on the Span Zero in a dua...

Page 48: ...ication tab Use span gas Click to verify the span gas Use zero gas Click to verify the zero gas Verify Click to begin verification Acceptable range Enter the acceptable error range value in percent La...

Page 49: ...f CG1100 Figure 4 9 Status tab on configurator software Oxygen reading Current oxygen reading in percent Cell temperature Current temperature in degrees C Flow Current sample flow in sccm Error box Ri...

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Page 51: ...yzer to Cal 4 Set the 3 way valve that delivers the calibration gases to Span Gas 5 Click the appropriate gas calibration button on the Calibrate tab Span Zero Span Only Zero Only for dual or single g...

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Page 53: ...eed to contact the factory for assistance Be sure to always include your analyzer model and serial number when call ing the factory for technical support Diagnostic checks are broken down as follows W...

Page 54: ...in1 TB3 Pin 2 TB3 Pin 3 24 Volts 24 VRet Chassis GND Red Black Green Yellow TB7 Pin 1 TB7 Pin 2 TB7 Pin 3 TB7 Pin 4 TB7 Pin 5 TB8 Pin 6 15 Volts GND Vout Chassis GND N C N C Brown Yellow Green Blue TB...

Page 55: ...n this same environment and check that the reading of the test meter measures the same temperature as the thermometer If the thermocouple measures the temperature incorrectly greater than 1 of expecte...

Page 56: ...ld Calibration Line Check Ensure that your calibration line is not contaminated with such things as pipe dope cutting fluid oil or solvents All these contaminants produce hydrocarbon vapors that inter...

Page 57: ...ge is present at terminals TB6 Pins 1 and 2 on the ana log board check for the DC furnace drive signal at terminals P1 Pins 20 and 8 at the analog board The furnace drive is a 5 VDC pulse train and de...

Page 58: ...e low calibration gas into the sensing portion of the analyzer Allow the gas to stabilize and then measure the cell mil livolts Using a voltmeter measure across Cell TB4 Pin 1 to Cell TB4 Pin 2 on the...

Page 59: ...le Replacement Furnace Replacement Board Replacement Flow Meter Replacement Follow these precautions when working on the sensor Disconnect the power source from the analyzer when servicing sys tem com...

Page 60: ...g on sensor plumbing 4 Remove the 4 small acorn nuts that hold the cell assembly plate onto the back cover of the analyzer and put aside do not discard Once the nuts are removed the assembly can be re...

Page 61: ...e cell in as you pull the O ring back away from the cell tee assem bly with your thumb and forefingers You should feel the cell contact collapse as you push the cell in You will need to apply extra pr...

Page 62: ...ll assembly through the hole in the analyzer ensuring that no portion of the cell clip wire is touching surround ing hardware 3 Slide the plate of the cell assembly over the standoffs around the hole...

Page 63: ...e removed as a single unit 2 Disconnect the thermocouple wires from TB5 on the analog board 3 Disconnect the furnace wires from TB6 on the analog board 4 Remove all inlet tubing Remove the T fitting f...

Page 64: ...nace as far as possible Hand tighten the nut Tighten with a wrench one quar ter turn 3 Place the new furnace into the furnace L bracket tighten the furnace captive screw Make sure that the furnace sit...

Page 65: ...handled or right angled screwdriver to facilitate removal LED Board 6 Connector Cable 9 Connector Cable LED Board 6 Connector Cable 9 Connector Cable Figure 7 6 LED board and connector cable locations...

Page 66: ...s a reference 1 Remove the 9 connector LED ribbon cable J2 from the upper right hand corner of the analog board 2 Remove the 2 position VSO valve connector TB2 from the top middle of the board 3 Remov...

Page 67: ...h with a 64 pin connector along the right hand side of the board They are very tightly connected Figure 7 8 10 Place your fingers between the analog board and the MCU board in the area of the 64 pin c...

Page 68: ...holding the board onto the PCB bracket Retain the standoffs and washers 5 Remove the remaining LED ribbon cable P5 located at the bottom of the board P4 RS 232 Connector P2 RS 485 Connector Standoffs...

Page 69: ...Service and Parts 7 11 TB2 TB3 TB6 TB4 TB5 J4 J1 P1 J2 VSO LED Cable Power Furnace Cell Thermocouple Mass Flow I O 64 Pin Connector Figure 7 10 Cable connector locations on the analog board...

Page 70: ...ent flow meter 4 Detach the ribbon cable connected to the analog board at position J4 Pressure Transducer Mass Flow Meter VSO Valve O Rings Manifold Nut Figure 7 11 Mass flow meter Replacing the mass...

Page 71: ...Service and Parts 7 13 5 Reconnect the inside tubing to the other end of the flow meter Mass Flow Meter Connector Connector Figure 7 12 Mass flow meter flow direction...

Page 72: ...90477VE MCU Board 305110901 Analog Board 80536SE Alarm and System Messages Board 80532SE RS 485 to RS 232 Converter 73858SE Terminator Plug 80544SE Bench Mount 24 Volt DC Power Supply 25446JE Cell Rep...

Page 73: ...ter hex 3E The End Flag is a carriage return hex 0D The Node address is a two byte hexadecimal ASCII value in the range 00 through FF Addresses F0 through FF are reserved The command byte is a single...

Page 74: ...ll mes sages with node address F0 Care must be taken to prevent multiple slaves from receiving commands with the broadcast address as this will cause a bus contention Normally node address F0 would be...

Page 75: ...n ASCII A will be sent Example slave A CR Acknowledge with Data If a command issued by the master requires data in response an Acknowl edge with Data response will be issued This response consists of...

Page 76: ...Write Data H or W The data field of this message contains a two character hex variable ID Note that each system variable will have an associated format The data to be written follows the ID The data f...

Page 77: ...illivolt reading for the zero gas C10 Save the cell millivolt reading for the span gas C31 Manually calibrate based on previously saved zero and span mil livolt readings C40 Manual verify using curren...

Page 78: ...y failure Electronics over temperature O2 concentration is changing Held Oxygen Percent 52 Value is held at last reading during calibration Oxygen Percent 08 Oxygen PPM 69 Pressure 4D Requires optiona...

Page 79: ...y in seconds after opening span gas valve Zero Delay 92 Delay in seconds after opening zero gas valve Sample Delay 93 Delay in seconds after opening sample gas valve Hold Out 71 0 Track 1 Hold last O2...

Page 80: ...0x0004 0x0008 0x0010 0x0020 0x0100 0x0200 Output System alarm Alarm 1 Alarm 2 Zero valve Span valve Alarm 3 Alarm 4 The following functions are used to emulate the CG1000 RTP Flow High Limit 7A High l...

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