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MODEL 1000

SEP 2005

MAINTENANCE

5-1

5.0

MAINTENANCE

This section provides instructions and checklists for maintaining or repairing the Model 1000 GC
System. This section is organized as follows:

Troubleshooting and Repair Concept

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Section 5.1

Routine Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Section 5.2

GC System Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1

Routine Maintenance Procedures

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2

Contract Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3

Locating and Gaining Access to Equipment Elements

. . . . . . . . . . . . . . . . . . .

See Section 5.3

Analyzer Electrical / Electronic Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1

Detector Elements, Heater Elements, Valves and Columns . . . . . . . . . . . . . . . . . . .

5.3.2

Precautions for Handling Printed Circuit Assemblies

. . . . . . . . . . . . . . . . . . .

See Section 5.4

Service, Troubleshooting, and Repair Instructions

. . . . . . . . . . . . . . . . . . . . .

See Section 5.5

Preamplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.1

Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.2

Decoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.3

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.3.1

Instructions for Removing the Decoder Board . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.3.2

Instructions for Reinstalling the Decoder Board

. . . . . . . . . . . . . . . . . . . . . . .

5.5.3.3

Analyzer Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.4

Flow Balance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.4.1

Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.4.2

Baseline Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.4.3

Leak-Checking the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.4.4

Plugged Lines, Columns, or Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.4.5

Chromatograph Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.5

Valve Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.5.1

Valve Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.5.2

Valve Overhaul Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.5.3

Detector Bridge Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.6

Temperature Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.7

Measure Vent Flow (MV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.8

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.9

Summary of Contents for Daniel Danalyzer 1000

Page 1: ...MODEL 1000 GAS CHROMATOGRAPH HARDWARE REFERENCE MANUAL Applies to both Daniel Danalyzer Model 1000 Rosemount Analytical Model 1000 Part Number 3 9000 541 Revision B SEPTEMBER 2005 ...

Page 2: ......

Page 3: ...URE THEIR ACCURACY THEY ARE NOT TO BE CONSTRUED AS WARRANTIES OR GUARANTEES EXPRESSED OR IMPLIED REGARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICABILITY WE RESERVE THE RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR SPECIFICATIONS OF SUCH PRODUCTS AT ANY TIME SELLER DOES NOT ASSUME RESPONSIBILITY FOR THE SELECTION USE OR MAINTENANCE OF ANY PRODUCT RESPONSIBILITY FOR PROPER SELE...

Page 4: ...by this limited warranty and shall be at Buyer s expense Seller shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by an authorized Seller representative All costs of dismantling reinstallation and freight and the time and expenses of Seller s personnel for site travel and diagnosis under this warranty clause s...

Page 5: ...nterfaces 1 9 1 5 2 Capabilities 1 10 1 6 THEORY OF OPERATION 1 11 1 6 1 The Analyzer Detector 1 11 1 6 2 Data Acquisition 1 13 1 6 3 Peak Detection 1 14 1 6 4 Basic Analysis Computations 1 16 1 7 GLOSSARY 1 19 2 0 EQUIPMENT DESCRIPTION 2 1 2 1 SAMPLING SYSTEM 2 2 2 1 1 Sampling Point Location 2 2 2 1 2 Sample Volume and Flow Rate 2 2 2 1 3 Sample Conditioning 2 3 2 1 4 Contamination Precautions 2...

Page 6: ...uts and Outputs 2 13 2 3 1 3 Communications 2 13 2 3 1 4 Driver Outputs 2 14 2 3 1 5 General Controller Specifications 2 14 2 3 1 6 Electrical Mechanical Safety and Integrity Certifications and Classifications 2 15 2 3 1 7 GC Controller Circuit Board List 2 16 2 3 2 Optional Keyboard and Display 2 21 2 3 2 1 Key Pad 2 21 2 3 2 2 Display 2 21 2 3 3 Alarm Specifications 2 21 2 3 3 1 Status Indicator...

Page 7: ...n for Short Distance RS 232 3 42 3 4 3 4 PC to GC Long Distance with RS 422 or RS 485 3 44 3 4 4 CPU and COM4A Serial Communications Setups 3 46 3 4 4 1 CPU RS 232 RS 422 RS 485 Configurations 3 50 3 4 4 2 CPU RS 232 Configuration 3 51 3 4 4 3 CPU RS 422 Configuration 3 53 3 4 4 4 CPU RS 485 Configuration 3 57 3 4 4 5 CPU COM1 COM2 Keyboard and Printer Output Header 3 59 3 4 4 6 CPU COM3 COM4 Outp...

Page 8: ...D ENTRY 4 3 4 1 1 Light Emitting Diode LED Indicators 4 3 4 1 2 Liquid Crystal Display LCD 4 4 4 1 3 Keypad 4 4 4 2 LOGGING ON TO VIEW OR EDIT DATA 4 7 4 2 1 First Time Log On 4 7 4 2 2 Subsequent Log On 4 8 4 2 3 Start Halt an Auto Sequence Analysis 4 9 4 2 4 Editing Procedures 4 11 4 2 5 Validity Checks of Data Entries 4 13 4 3 LOCAL DISPLAY MENUS 4 14 4 3 1 Main Menu 4 15 4 3 2 Hardware Menu 4 ...

Page 9: ...R INSTRUCTIONS 5 9 5 5 1 Preamplifier 5 11 5 5 2 Temperature Control 5 11 5 5 3 Decoder 5 11 5 5 3 1 Fuse Replacement 5 11 5 5 3 2 Instructions for Removing the Decoder Board 5 11 5 5 3 3 Instructions for Reinstalling the Decoder Board 5 13 5 5 4 Analyzer Troubleshooting Guide 5 14 5 5 4 1 Flow Balance Check 5 14 5 5 4 2 Temperature 5 14 5 5 4 3 Baseline Drift 5 15 5 5 4 4 Leak Checking the Analyz...

Page 10: ...ted Calibration 5 42 5 8 6 Analog Loopback Test Circuits 5 44 5 8 7 Upgrading Analog Outputs 5 46 5 9 DISCRETE DIGITAL INPUTS AND OUTPUTS 5 47 5 9 1 Digital Loopback Test Circuit 5 47 5 10 FUSE PROTECTION 5 48 5 11 ANALYZER CONTROLLER INTERCONNECT 5 49 5 11 1 Function Codes 5 51 6 0 RECOMMENDED SPARE PARTS 6 1 6 1 ANALYZER SPARES 6 1 6 1 1 Printed Circuit Card Assemblies Analyzer 6 1 6 1 2 Electri...

Page 11: ...rt of GC to DB 25 Port of Modem A 9 A 4 Example RS 422 Connection from PC to GC A 10 A 5 Example RS 485 Connection from PC to GC A 12 B MANIFOLD FOR TWO CARRIER GAS BOTTLES TO GC SYSTEM B 1 B 1 Illustration B 2 B 2 Installation and Line Purging B 3 B 3 Replacing Carrier Cylinder B 4 C GUIDE TO TRANSIENT PROTECTION MODULES C 1 C 1 Purpose of the Transient Protection Modules C 1 C 2 Part Application...

Page 12: ...SEP 2005 MODEL 1000 TABLE OF CONTENTS x ADDENDA Addendum Page 1 ANALYZER DRAWINGS Addendum 1 1 2 GC CONTROLLER DRAWINGS Addendum 2 1 ...

Page 13: ...l provides the following information Section 1 Description A general description of the Model 1000 Gas Chromatograph GC System and its components their configurations and functions A brief description of the GC System s software user interfaces and capabilities Introduction to GC theory of operation and terminology Section 2 Equipment Description Guidelines for sampling system and gas connections ...

Page 14: ...if provided Section 5 Maintenance Instructions for regular maintenance and care of the GC System hardware Instructions for troubleshooting repair and service of the GC System hardware Section 6 Recommended Spare Parts List of boards valves and other components suggested as spare parts Appendices Appendices with additional helpful reference materials and drawings ...

Page 15: ...oller Located either integrally in the upper enclosure or made for mounting on a standard 19 inch rack in a nonhazardous protected area with or without a built in keyboard and LCD The GC Controller includes electronics and ports for signal processing instrument control data storage personal computer PC interface and telecommunications Rack Mount Suitable for use in a nonhazardous environment Sampl...

Page 16: ...atographs via RS 485 serial communications links The PC is used to display analysis chromatograms and reports which can then be stored to files on the PC hard drive or printed from either the PC s printer port or the GC Controller s printer port Also each individual GC Controller can be operated from its built in keyboard and LCD if installed in that configuration however this method offers more l...

Page 17: ...nto its constituent components A detector located at the outlet of the analytical column senses the elution of components from the column and produces electrical outputs proportional to the concentration of each component Outputs from the Analyzer detectors are amplified in the Analyzer electronics then transmitted to the GC Controller for further processing See also Section 1 6 Theory of Operatio...

Page 18: ...SEP 2005 MODEL 1000 DESCRIPTION 1 6 Figure 1 1 GC System Functional Block Diagram ...

Page 19: ...d the user must download Socket 2 from www microsoft com windows95 downloads to utilize MON2000 s Ethernet feature Windows 98 version 1 or later Windows 2000 version 1 or later Windows XP version 1 or later see note for system requirements Windows NT version 4 service pack 3 or later 16 megabytes MB of RAM 32 MB or higher recommended 5 MB of free hard disk space Super VGA monitor with 800x600 reso...

Page 20: ...0 the version number should be 1 or later To use Windows XP you need Computer Processor PC with 300 MHz or higher processor clock speed recommended 233 MHz minimum required single or dual processor system Intel Pentium Celeron family or AMD K6 Athlon Duron family or compatible processor recommended Memory 128 MB of RAM or higher recommended 64 MB minimum supported may limit performance and some fe...

Page 21: ...plete user instructions for MON2000 in the program s online HELP screens and in the program user s manual MON2000 Software for Gas Chromatographs User Manual P N 3 9000 522 or The GC Controller s built in keyboard and LCD The GC Controller s optional built in keyboard and LCD offer essential startup and operation functions They are useful in a hazardous environment or if no PC is available See Sec...

Page 22: ...es halt operation stream detector assignments stream component table assignments stream calculation assignments diagnostics alarm and event processing event sequence changes component table adjustments calculation adjustments alarm parameters adjustments analog scale adjustments Reports and logs that can be produced depending upon the GC Application in use include but are not limited to the follow...

Page 23: ...anations 1 6 1 Analyzer Detector The Analyzer detector subsystem is a thermal conductivity detector that consists of a balanced bridge network with heat sensitive thermistors in each leg of the bridge Each thermistor is enclosed in a separate chamber of the detector block One thermistor is designated the reference element and the other the measurement element A schematic diagram of the thermal con...

Page 24: ...e change in detector electrical output during elution of a component Figure 1 3 Detector output during component elution 1 Detector bridge balanced 2 First component begins to elute from column and to be sensed by the measurement thermistor 3 Peak concentration of first component 4 Second component begins to elute from column and to be sensed by the measurement thermistor 5 Peak concentration of s...

Page 25: ...ata rate to 40 N samples second For example if N 5 then a total of 40 5 or 6 averaged data samples are stored every second The value for the variable N is determined by the selection of a Peak Width parameter PW The relationship is N PW seconds where PW is given in seconds All the various details in the analysis process are independent of the value of N Allowable values of N are 1 to 63 which corr...

Page 26: ...ive and higher values make detection less sensitive Higher values 20 to 100 would be appropriate for noisy signals e g high amplifier gain Peak termination is determined by the same application of this detector to the signal but in the reverse sense Onset is defined where the detector output exceeds the baseline constant but termination is defined subsequently where the detector output is less tha...

Page 27: ...ak of the discrete valued curve stored in the GC Controller For fused peak sequences this interpolation technique is used both for peaks as well as valleys minimum points In the latter case lines are dropped from the interpolated valley points to the zero reference line to partition the fused peak areas into individual peaks The use of quadratic interpolation improves both area and height calculat...

Page 28: ...r determined automatically by the system through calibration procedures with a calibration gas mixture that has known concentrations Response factor calculation using the external standard or Where n ARF Area response factor for component n in area per mole percent n HRF Height response factor for component n n Area Area associated with component n in calibration gas n Ht Height associated with co...

Page 29: ...larm has been previously entered by the operator Concentration Calculations in Mole without Normalization Once response factors have been determined by the GC Controller or entered by the operator component concentrations are determined for each analysis by using the following equations or Where n CONC Concentration of component n in mole n Area Area of component n in unknown sample n ARF Response...

Page 30: ...ntration Calculations with Normalization Where n CONCN Normalized concentration of component n in percent of total gas concentration n CONC Non normalized concentration of component n in mole i CONC Non normalized concentration in mole from each of the k components to be grouped into this normalization k Number of components to be included in the normalization For additional information about othe...

Page 31: ... processed on a PC VGA display Tick marks recorded on the chromatogram by the GC Controller indicate where timed events take place Component Any one of several different gases that may appear in a sample mixture For example natural gas usually contains the following components nitrogen carbon dioxide methane ethane propane isobutane normal butane isopentane normal pentane and hexanes plus Condulet...

Page 32: ...n calibration gas Amount of component n in mole in calibration gas Retention Time The time in seconds that elapses between start of analysis 0 seconds and the sensing of the maximum concentration of each component by the Analyzer detector RI Ring indicator a serial port pin assignment RLSD Received line signal detect a digital simulation of carrier detect see also DCD a serial port pin assignment ...

Page 33: ...matograph Valves 2 2 2 Primary Plate 2 2 2 1 Actuating Subassemblies 2 2 2 2 Operation 2 2 2 3 Detector Subsystem 2 2 3 Analyzer Preamplifier Unit 2 2 4 Analyzer Specifications 2 2 5 Utility Gas Requirements 2 2 6 Controller See Section 2 3 Controller Hardware Configurations 2 3 1 Analog Inputs and Outputs 2 3 1 1 Digital Inputs and Outputs 2 3 1 2 Communications 2 3 1 3 Driver Outputs 2 3 1 4 Gen...

Page 34: ...le flowing to the sample valve The following points should be considered in selecting and installing a sampling system Sample Paint Sample Volume and Flow Rate Sample Conditioning Contamination Precautions Valving Calibration Gas 2 1 1 Sampling Point Location Gas samples must be representative of the process stream and must be taken from a location where stratification or separation of components ...

Page 35: ...ains approximately 1 cc of volume per foot Therefore with a flow rate of 50 cc per minute the lag time of the sample between the sample point and the Analyzer is calculated by dividing the length of the line in feet by 50 For example the sample in a 100 foot sample line will take 2 minutes to travel the length of the line 2 1 3 Sample Conditioning Sample systems should contain at least one filter ...

Page 36: ... the National Bureau of Standards NBS If the calibration standard is a gas the standard should not have any component that could drop out at the coldest temperature to which the gas will be subjected A typical blend for a temperature of zero degrees Fahrenheit 0 F is listed in the following table No dropout will occur in this calibration gas if it is blended at a pressure below 250 psig Table 2 1 ...

Page 37: ...the sample and carrier gases Valve control Heater block temperature control Detector control Detector output signal preamplifier GC Controller with optional keypad display The lower section is temperature controlled and contains Detector elements Analytical columns A temperature controlled heater block The GC is mounted in a self supporting rack that may be placed at or near the sample tap Under m...

Page 38: ...SEP 2005 MODEL 1000 EQUIPMENT DESCRIPTION 2 6 Figure 2 1 Analyzer Components ...

Page 39: ...Figure 2 2 Chromatograph Valve 2 2 2 Chromatograph Valves A chromatograph valve is shown in Figure 2 2 in exploded view Its pistons are pneumatically actuated in both switching directions by the actuating assemblies located below the primary plate ...

Page 40: ...t the primary plate This closes the passages that are connected at the bottom of the plate When pressure is removed the pistons are free to move and flow is resumed through the passages 2 2 3 Detector Subsystem The operation of the Analyzer detector subsystem was previously discussed in the Theory of Operation section of this manual 2 2 4 Analyzer Preamplifier Unit The electrical output from the d...

Page 41: ...National Electrical Code NEC Area Classification Suitable for NEC Class 1 Division 1 Group D f Frame Size approximately Height 78 inches 198 centimeters cm Width 24 inches 61 cm maximum Depth 24 inches 61 cm g Weight Approximately 125 pounds 56 8 kilograms kg including mounting hardware h Sample Requirements 1 Fluid Phase Vapor 2 Pressure 15 to 30 psig regulated to 10 percent 3 Flow Rate 50 cc min...

Page 42: ...other devices The Controller provides both analog outputs and a direct digital link with output devices through RS 232C RS 422 or RS 485 ports Volatile portions of the program are protected by a lithium battery backup if power is lost or turned off at the unit The GC Controller can be linked directly to a PC by serial connection by a telecommunication link that uses Modbus protocol or ethernet con...

Page 43: ... 2 3 The unit consists of an STD bus based computer and related boards including boards for terminating field wiring The enclosure for hazardous areas qualifies as flameproof purged NEMA 4X Class C and D Connections to the enclosure are through one 2 inch 50mm hole reduced to 3 4 inch with bushing and two 1 inch 25 mm conduit fittings located in the bottom These accept matching conduit or cable en...

Page 44: ... switching assembly with either AC or DC solenoids can be controlled by the GC Controller allowing for switching up to 12 streams 2 3 1 1 Analog Inputs and Outputs The GC Controller can accommodate eight fully differential analog 4 to 20 mA input signals Four of the analog inputs are used by the associated Analyzer and they are filtered with transient protection The additional four input ports pro...

Page 45: ...alarms optically isolated with transient protection 3 front panel indicators green yellow red The digital transient protected discrete outputs can furnish up to 50 mA If more current is required up to 0 5A a special transient protection plug in module should be installed see Appendix C this manual for transient protection module details 2 3 1 3 Communications There are 3 to 8 communication ports e...

Page 46: ...on has the net effect of adding only seven more stream routes to the standard stream capacity of five thus giving a total stream capacity of twelve The reason is when the optional stream switch assembly is installed one of the Analyzer s standard five stream routes becomes dedicated to the optional stream switch assembly 2 3 1 5 General Controller Specifications a Power requirements without curren...

Page 47: ...I Division 1 Groups C and D and Canadian Standards Association C S A 22 2 No O M1962 Part II and C S A 22 2 No 30 M1986 for NEC Class I Division 1 Groups C and D EEx d IIB T6 Meets CENELEC EN 50 014 and EN 50 018 Electrical Apparatus for Potentially Explosive Atmospheres Parts 1 and 5 as flameproof for Group II Subdivision B Temperature Class T6 The GC Controller when housed inside purged enclosur...

Page 48: ...ications Commission FCC Part 15 Subparts A and B 2 3 1 7 GC Controller Circuit Board List The GC Controller circuit boards are inserted or attached to an STD bus card cage assembly It has two boards inserted into the card cage and two of the boards are attached to the card cage outside see Figure 3 7 There are three optional piggy back boards which can attach to the CPU Board via the PC 104 bus 1 ...

Page 49: ... system memory RS 422 serial protocol three timers digital I O and Disk on Chip Additional memory for higher capacity data archives DE 20782 COM4A Board CPU Daughter board Control of COM5 8 BE 20767 Modem CPU Daughter board telephone modem Analog I O board requires MON2000 software version 2 3 or later Analog Control of eight analog inputs 4 for user applications and 4 for Analyzer Controller inte...

Page 50: ...nputs and outputs Controller Analyzer interconnections Parallel printer port and Optional stream switching assemblies See drawing DE 20782 for an illustration of the GC Controller s Terminal Board for Field Wiring The GC Controller s Terminal Board for Field Wiring also has sockets for transient protection modules and a 250 VAC 2A fuse 5 x 20 mm that protects all of the boards from transient surge...

Page 51: ...s and outputs Switching power supply and temperature shutdown circuit for the LCD display RS 232 to RS 422 conversion for the LCD display and Voltage to current conversion for the analog outputs Jumper for selecting driving voltage source for the 4 20 mA circuit See drawing CE 18118 for an illustration of the System Interface and Driver board Also see Figure 2 5 next page It illustrates through a ...

Page 52: ...SEP 2005 MODEL 1000 EQUIPMENT DESCRIPTION 2 20 Figure 2 5 Block Diagram of GC Controller Circuit Boards ...

Page 53: ...d on the top of the keys will be displayed entered when the ALT key is not pressed 2 3 2 2 Display The Controller display measuring 5 5 x 2 inches is capable of 8 lines by 41 characters It is certified for use with a purged NEMA 4X Class C and D enclosure The display is capable of producing the complete alphabet and numbers from the keypad The video display on the Controller may show a truncated o...

Page 54: ...larm s This indicator is partially application controlled and may be set at different out of tolerance levels with different applications Green LED When illuminated the Green LED indicates that the Controller is operating If the green LED is illuminated and the Controller does not accept changes a password lockout may have been entered If a password has been entered the password must be re entered...

Page 55: ... Table 3 1 for a summary of installation and setup steps Precautions and Warnings See Section 3 1 Hazardous Environments 3 1 1 Power Source Wiring 3 1 2 Signal Wiring 3 1 3 Electrical and Signal Ground 3 1 4 Electrical Conduit 3 1 5 Sample Systems Requirements 3 1 6 Preparation See Section 3 2 Introduction 3 2 1 Site Selection 3 2 2 Unpacking the Unit 3 2 3 Necessary Tools and Components 3 2 4 Opt...

Page 56: ...er 3 4 4 5 CPU COM3 COM4 Output Header 3 4 4 6 COM4A RS 232 RS 422 RS 485 Configuration 3 4 4 7 COM4A RS 232 Configuration 3 4 4 8 COM4A RS 422 Configuration 3 4 4 9 COM4A RS 485 Configuration 3 4 4 10 Parallel Printer Interface 3 4 4 11 P C104 Bus Interface 3 4 4 12 Silicon Disk Configuration 3 4 4 13 Multi I O Connector 3 4 4 14 Parallel I O Configuration 3 4 4 15 Controller Printer Wiring 3 4 5...

Page 57: ...tion see Section 3 2 3 Obtain Supplies and Tools see Section 3 2 4 Install Analyzer Wiring see Section 3 3 5 Install Analyzer Sample Gas Lines see Section 3 3 6 Install GC Controller Wiring see Section 3 4 7 Perform Leak Checks see Section 3 5 8 Purge Carrier Gas Lines see Section 3 5 9 Purge Calibration Lines see Section 3 5 10 Start Up GC System see Section 3 6 ...

Page 58: ...ns of these or any attached equipment in which the installation or operation thereof has been performed in a manner that is negligent and or non compliant with applicable safety requirements EQUIPMENT DAMAGE OR PERSONAL INJURY The responsible body shall operate the equipment as designed and specified by the manufacturer Failure to do so may cause personal injury or damage to the equipment 3 1 1 Ha...

Page 59: ...the GC Controller are made through purged conduit or flameproof glands EQUIPMENT DAMAGE OR PERSONAL INJURY Observe ALL applicable regulations when installing purged GC units Failure to observe all regulations when installing purged GC units may result in noncompliance equipment damage or personal injury The purged GC Controller and Analyzer housings are certified for use in locations where fire an...

Page 60: ...isconnect device b For Rack mount units the power disconnect switch shall be in close proximity to the equipment and easily accessible to the operator 4 Provide 20 ampere circuit breaker protection so that the major components of the GC system the Analyzer the GC Controller and any optionally installed sample oven or stream switching devices are all protected by one circuit breaker 5 Use multi str...

Page 61: ...the conduit and cable shielding 3 Use suitable lubrication for wire pulls in conduit to prevent wire stress 4 All process signal wiring should be a single continuous length between field devices and the GC Controller If however length or conduit runs require that multiple wiring pulls be made the individual conductors must be interconnected with suitable terminal blocks 4 Use separate conduits for...

Page 62: ...s signal common isolated from earth chassis ground Applicable to the digital and analog I O lines connecting to the GC Controller including the Analyzer Controller Interconnect lines Any loop of extra cable left for service purposes inside the GC Controller purged housing must not be placed near the conduit entry for AC power If the above precaution is not followed the data and control signals to ...

Page 63: ...lug color green is located on the inside bottom front of the GC Controller s case Chassis ground conductors color code green inside the Controller s enclosure should be stranded insulated copper wire These device chassis ground conductors should all be connected to the clamp type ground lug 4 A clamp type ground lug is located on the outside of the GC Controller s case at the rear of the lower rig...

Page 64: ... 4 6 meters length 15 to 30 feet AWG 6 stranded insulated copper wire 4 6 to 9 1 meters length 30 to 100 feet AWG 4 stranded insulated copper wire 9 1 to 30 5 meters 8 All inter enclosure equipment grounding conductors must be protected by metal conduit 9 External equipment such as data printers that are connected to the GC Controller should be powered via isolation transformers to minimize the gr...

Page 65: ... dirt or other contaminants If necessary swab out conduits prior to installing the conductors 4 Install drain fittings at the lowest point in the conduit run install seals at the point of entry to the GC Controller s purged housing to prevent vapor passage and accumulation of moisture 5 Use liquid tight conduit fittings such as Myers Scru Tite or similar for conduit which is exposed to moisture Wh...

Page 66: ...E OR PERSONAL INJURY Consult your company s policies and procedures and other applicable requirements documents to determine wiring and installation practices that are appropriate for hazardous areas Failure to do so may cause personal injury or damage to equipment ...

Page 67: ...an and free of grease Dryers and Filters in Sample Line Use small sizes to minimize time lag and prevent back diffusion Install a minimum of one filter to remove solid particles Most applications require fine element filters upstream of the Analyzer Do use ceramic or porous metallic type filters Do not use cork or felt filters Pressure Regulators and Flow Controllers in Sample Line Do not use type...

Page 68: ...ing Follow these guidelines for site selection 1 Provide adequate access space for performing maintenance and adjustments a Allow a minimum of 3 feet 9 m in front for operator access b Allow a minimum of 15 inches 38 cm at the rear and left side for case removal c If possible mount the Analyzer components in a vertical stack configuration it provides the greatest operator convenience 2 Install the...

Page 69: ...hromatographs User Manual P N 3 9000 522 c CD s with the MON2000 software program and GC Applications Installation and startup of the GC System should proceed only if all required materials are on hand and free from obvious defects If any parts or assemblies appear to have been damaged in shipment first file a claim with the carrier Next complete a full report of the nature and extent of the damag...

Page 70: ... standard gas with correct number of components and concentrations see Section 2 1 6 this manual 4 Dual stage regulator for the calibration gas cylinder low pressure side capable of controlling pressure up to 30 psig 5 Sample probe fixture for procuring the stream or sample gas for chromatographic analysis 6 1 8 inch stainless steel SS tubing for connecting calibration standard to analyzer 1 4 inc...

Page 71: ...L 1000 SEP 2005 INSTALLATION AND SETUP 3 17 9 Liquid leak detector SNOOP or equivalent 10 Digital volt ohm meter with probe type leads 11 A flow measuring device such as Alltech Digital Flow Check Flowmeter ...

Page 72: ... Controller and a serial port of the PC For details see Section 3 4 3 SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Do not operate a PC or printer in a hazardous environment Failure to observe all safety precautions could result in serious injury or death If you are working in a hazardous area and need to perform routine operations use the optional keyboard and LCD that are built into the purged GC Co...

Page 73: ...de conduit for hazardous environments For cable termination details see Section 3 3 1 this manual 4 Direct Serial Connect Cable P N 3 2350 068 to connect the PC or an external modem directly to the one of the GC Controller s serial ports on the GC Controller s Terminal Board for Field Wiring TB This cable comes in a customer specified length It is terminated with a DB 9 female plug at one end for ...

Page 74: ...g connections between the Analyzer and the GC Controller follow these steps 1 Disconnect all electrical power to both the Analyzer and the GC Controller 2 Feed the Interconnect Cable through the inlet on the condulet box on top of the upper enclosure and make connections to the interconnect terminal board TB 4 which lies behind Valve Driver Board see Figure 3 2 a The Interconnect Cable is computer...

Page 75: ... 4 Carefully edge the Valve Driver Board off the holding screws Do not disconnect the Valve Driver Board from the cable merely let the board rest face down secured by the cable see Figure 3 2 5 With the Analyzer TB 4 now exposed connect thirteen of the Interconnect Cable s fifteen leads to terminals 11 through 23 See Table 3 2 and Figure 3 3 for purposes and destinations of leads Also see CAUTION ...

Page 76: ...SEP 2005 MODEL 1000 INSTALLATION AND SETUP 3 22 Figure 3 2 Valve Driver Board Resting Face Down from its Cable Allows Access to TB 4 ...

Page 77: ...inal 3 Terminal 14 Function code 8 J19 Terminal 4 Terminal 15 Function code strobe J20 Terminal 1 Terminal 16 Common function codes J19 Terminal 5 Terminal 17 Auto Zero AZ J20 Terminal 2 Terminal 18 Preamp gain channel 1 J18 Terminal 1 Terminal 19 Preamp gain channel 2 J18 Terminal 4 Terminal 20 Preamp gain channel 3 J18 Terminal 7 Terminal 21 Preamp gain channel 4 J18 Terminal 10 Terminal 22 Comm...

Page 78: ...oncerning signal wiring Failure to properly connect the GC unit may result in serious equipment damage or personal injury 6 Access the GC Controller s Terminal Board for Field Wiring TB and connect the other leads of the Interconnect Cable to the GC Controller s TB see instructions in Section 3 4 2 Ensure that the connections correspond to those listed in Table 3 2 and Figure 3 3 a At this time yo...

Page 79: ...MODEL 1000 SEP 2005 INSTALLATION AND SETUP 3 25 Figure 3 3 Analyzer and GC Controller Interconnect Leads ...

Page 80: ...and ground but do not turn on AC power to the Analyzer yet see CAUTION below see details for AC power connection to Analyzer in Section 3 3 2 this manual EQUIPMENT DAMAGE OR PERSONAL INJURY Do not apply AC electrical power to the Analyzer or the GC Controller until all electrical power interconnection and external signal connections have been verified and proper grounds have been made Failure to p...

Page 81: ... a customer power NPT connection at the top of the Analyzer stack b Leads are colored as follows HOT black NEUTRAL white GROUND green 2 Connect Analyzer AC power leads to properly controlled 115 volts AC power source i e with circuit breaker and power disconnect switch SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Do not connect AC power leads without first ensuring that AC power source is switched OF...

Page 82: ...ower interconnection and external signal connections have been verified and proper grounds have been made Failure to properly connect the GC unit may result in serious equipment damage or personal injury 3 If necessary connect the Analyzer s chassis ground to an external copper ground rod at remote locations See Section 3 1 4 this manual regarding electrical and signal ground ...

Page 83: ... Analyzer Sample Vent SV line 1 16 inch tubing marked SV located at the left side of the Analyzer At this stage in the installation the Analyzer Measure Vent MV line marked MV is left plugged until Analyzer leak checks are completed For regular Analyzer operation however the MV line must be unplugged or open HINT Do not discard the vent line plugs They are useful at any time when leak checking the...

Page 84: ...g low side capacity 150 psig 3 Connect calibration standard gas to Analyzer DO NOT TURN ON GAS AT THIS TIME a Use 1 8 inch stainless steel tubing to conduct calibration standard gas b Use dual stage regulator low side capacity up to 30 psig c Calibration gas inlet is identified in the applicable Sample Conditioning System S C S drawing in the Analyzer drawings addendum to this manual See drawings ...

Page 85: ...15 30 psig 10 c Sample gas stream inlet s are identified in the applicable Sample Conditioning System S C S drawing in the Analyzer drawings addendum to this manual See drawings CE 16120 CE 16220 CE 16320 CE 16420 or CE 16520 5 After all lines have been installed proceed with Controller wiring connections see next section a Leak check procedures for the GC sample and gas lines are given in Section...

Page 86: ...ases the COM ID setup made at the factory will not require changes Unless otherwise specified by the customer the DIP switch settings made at the factory give the Controller a COM ID of 1 one This section applies only to GC systems which have not been shipped prewired or may not have had the COM ID set according to customer specifications Follow the steps in this section only if you wish to do the...

Page 87: ...om the GC Controller make certain the power supply switch is OFF and the AC power cord is disconnected Observe all safety precautions when you are working in a hazardous environment Failure to observe all safety precautions could result in serious injury or death 2 For integrally mounted Controllers use a flat head screw driver to remove the access panel on the right side of the card cage assembly...

Page 88: ...ng O Switches 1 through 5 form a 5 bit binary number for setting the Modbus slave address also known as COM ID or Device ID O Switch number 1 is the least significant bit and switch number 5 is the most significant bit O Switch to ON 1 Switch to OFF 0 O Switch 6 is a spare for future use Switches 7 and 8 are set as needed for the presence of an optional LOI Local Operator Interface connected via C...

Page 89: ...FF ON OFF OFF 5 ON OFF ON OFF OFF 6 OFF ON ON OFF OFF 7 ON ON ON OFF OFF 8 OFF OFF OFF ON OFF RAM CLEAR Dip Switch Setting Switch Positions 8 Clears RAM when unit powered down ON Keeps RAM when unit powered down OFF 4 When finished with the inspection or changes reassemble the Controllers using the following steps a For integrally mounted Controllers reattach the right side Access Panel and secure...

Page 90: ...g to the GC Controller including the Analyzer Controller Interconnect lines Any loop of extra cable left for service purposes inside the GC Controller purged housing must not be placed near the conduit entry for AC power If the above precaution is not followed the data and control signals to and from the GC Controller can be adversely affected To make wiring connections between the GC Controller a...

Page 91: ...rocedures without removing the enclosure 4 Locate the GC Controller s Terminal Board for Field Wiring TB The TB is attached to the GC Controller s card cage assembly facing the enclosure s front panel In the rack mount Controller the TB faces outward toward the rear of the enclosure 5 Route the Analyzer Controller Interconnect Cable appropriately especially in the case of the purged Controller enc...

Page 92: ...ddresses the various possibilities for wiring a serial connection between a PC and the GC System 3 4 3 1 Before Connecting Before connecting a PC to the GC Controller determine the following 1 What serial ports are available at the PC When you select one consider these points a FACT Standard PC serial ports are type RS 232 b Usually there are two external serial port jacks on a PC located on the r...

Page 93: ...hich port can be used for connecting to the GC Controller note existing serial connections refer to your PC user s manual and use diagnostic software such as Norton Utilities 2 What serial ports are available at the GC Controller When you select one consider these points a The GC Controller s COM1 serial channel is usually reserved for connecting a PC especially for service or troubleshooting purp...

Page 94: ...llection Systems DCS or multi drop serial data highway system and thus would be unavailable for a serial PC connection 3 Is the connection to be made in a Nonhazardous environment Short distance between the PC and Controller With temporary or permanent cable connection a See Section 3 4 3 2 PC to GC Front Panel Quick and Easy RS 232 4 Is the connection to be made in a Hazardous or nonhazardous env...

Page 95: ...including serial port are made through explosion proof conduit or flameproof glands Failure to observe all safety precautions could result in serious injury or death 1 Obtain a straight through serial cable a 50 feet long or less b DB 9 or DB 25 female plug at one end for PC connection and c DB 9 male plug at the other end for GC connection d You can buy this type of cable with plug ends already i...

Page 96: ... jacks proceed as follows 1 Access the GC Controller s Terminal Board for Field Wiring TB a If necessary see instructions provided in Section 3 4 1 step 1 2 Choose an available serial port on the TB that is configured for RS 232 serial protocol Unless specified otherwise by customer order all serial channels on all versions of the GC Controller are configured by default from the factory for RS 232...

Page 97: ...igured for RS 232 as shown in Table 3 4 Table 3 4 Direct serial connect cable P N 3 2350 068 Function at PC s serial port Pin number of the female DB 9 plug Exposed lead color Connect exposed leads to one of GC Controller RS 232 serial COM ports on Terminal Board TB for field wiring J5 J6 J10 or J11 pin number DCD RLSD 1 red 1 DCD RLSD IN OUT S RxD 2 white 2 S TxD OUT IN S TxD 3 black 3 S TxD GND ...

Page 98: ...al for example brand and model b Shielded computer grade twisted pair cable to connect the asynchronous line driver device to the GC c A straight through serial cable to connect the PC to the line driver 2 Connect the straight through serial cable from the PC s serial port to the RS 232 serial port of the line driver device Then connect the twisted pair cable to the RS 422 RS 485 serial port of th...

Page 99: ...e Appendix A this manual for example connection Also see Section 3 4 4 this manual for list of ports and terminals assigned to serial communications When the unit has the COM4A Board installed COM8 is used for the display keyboard However if the unit does not have the COM4A Board installed the display keyboard uses COM4 and it must be RS 232 Therefore there is no COM4 output on the Field Terminati...

Page 100: ...S 485 The serial signal definitions and the ports that support them are as follows PC104 CPU RS 232 RS 422 RS 485 J5 J6 J10 and J11 and DB 9 ports P2 and P3 J5 J6 J10 and J11 and DB 9 ports P2 and P3 J5 J6 J10 and J11 and DB 9 ports P2 and P3 COM4A RS 232 RS 422 RS 485 Com 5 P22 Com 6 P23 Com 7 P24 Com 5 P22 Com 6 P23 Com 7 P24 Com 5 P22 Com 6 P23 Com 7 P24 The serial ports and terminals listed ab...

Page 101: ... 422 or RS 485 are most commonly used for long distance serial communications systems such as a Data Collection System or a multi drop serial data highway network For these systems the GC Controller can communicate as a Modbus slave device In any Modbus host slave DCS or multi drop serial data highway network there must only be one host to which any one of the GC Controller s serial ports can resp...

Page 102: ...s Terminal Board for Field Wiring TB a If necessary see instructions in Section 3 4 1 step 1 2 Route serial communications lines appropriately especially in the case of the explosion proof Controller enclosure 3 Make serial communications line connections to the GC Controller TB The port numbers and pinouts are listed in the following Serial Specifications Sections 3 4 4 1 through 3 4 4 3 ...

Page 103: ...ous combinations available for GC Controller serial communications ports i e RS 232 RS 422 or RS 485 require the following Specific jumper settings on the CPU Board P N 20765 and COM4A Board P N 20766 and Specific transient protection modules on the Controller s TB ...

Page 104: ...igurations The WinSystems CPU P N LPM MCM 6117 provides four RS 232 serial channels onboard configurable as RS 422 or RS 485 with the addition of optional driver IC s The configuration options for each of the supported modes are shown on the following pages Figure 3 9 CPU Configuration ...

Page 105: ...nector at J1 The configuration details and the pin definitions when used with the cable P N 3 2350 083 are shown here Figure 3 10 COM1 RS 232 CPU COM2 RS 232 Configuration COM2 is I O mapped at 2F8H and utilizes a 16550 type UART contained in the Super I O chip When used in RS 232 mode COM2 is terminated via the multi I O connector at J1 The configuration details and the pin definitions when used ...

Page 106: ...configuration details and the pin definitions when used with the cable P N 3 2350 087 are shown here Figure 3 12 COM3 RS 232 CPU COM4 RS 232 Configuration COM4 is I O mapped at 2E8H and utilizes a 16550 type UART contained in the 16C532 companion chip When used in RS 232 mode COM4 is terminated via the connector at J6 The configuration details and the pin definitions when used with the cable P N 3...

Page 107: ...hannel of RS 422 If two channels of RS 422 are required then two kits will be needed RS 422 is a 4 wire point to point full duplex interface allowing much longer cable runs than are possible than with RS 232 The differential transmitter and receiver twisted pairs offer a higher degree of noise immunity The following illustrations show the correct jumpering driver IC installation and I O connector ...

Page 108: ...2 If two channels of RS 422 are required then two kits will be needed RS 422 is a 4 wire point to point full duplex interface allowing much longer cable runs than are possible than with RS 232 The differential transmitter and receiver twisted pairs offer a higher degree of noise immunity The following illustrations show the correct jumpering driver IC installation and I O connector pin definitions...

Page 109: ...2 If two channels of RS 422 are required then two kits will be needed RS 422 is a 4 wire point to point full duplex interface allowing much longer cable runs than are possible than with RS 232 The differential transmitter and receiver twisted pairs offer a higher degree of noise immunity The following illustrations show the correct jumpering driver IC installation and I O connector pin definitions...

Page 110: ...2 If two channels of RS 422 are required then two kits will be needed RS 422 is a 4 wire point to point full duplex interface allowing much longer cable runs than are possible than with RS 232 The differential transmitter and receiver twisted pairs offer a higher degree of noise immunity The following illustrations show the correct jumpering driver IC installation and I O connector pin definitions...

Page 111: ...ent to configure two of the channels for RS 485 RS 485 is a 2 wire multi drop interface where only one station at a time talks transmits while all others listen receive The following illustrations show the correct jumpering driver IC installation and I O connector pin out for each of the COM1 channels when used in RS 485 mode CPU COM1 RS 485 Configuration Figure 3 18 COM1 RS 485 CPU COM2 RS 485 Co...

Page 112: ...SEP 2005 MODEL 1000 INSTALLATION AND SETUP 3 58 CPU COM3 RS 485 Configuration Figure 3 20 COM3 RS 485 CPU COM4 RS 485 Configuration Figure 3 21 COM4 RS 485 ...

Page 113: ...CPU J6 to the System Interface Board J8 and J10 This provides access to COM3 on J10 and COM4 on J11 of the Field Termination Board The serial port setup in the MON2000 Software for COM4 must be selected as a PC port For a system WITH a keyboard and display connect cable P N 3 2350 087 from CPU J6 to the System Interface J8 and J12 This provides access to COM3 on J10 and COM4 is dedicated for use a...

Page 114: ...gnal levels An optional Chip Kit P N 3 2350 115 is necessary to allow configuration of a single channel for RS 422 use or up two channels of RS 485 usage If four channels of RS 422 use is desired four P N 3 2350 115 Kits will be required Configuration of each channel consists of installing and or removing the appropriate line driver ICs and installing the required jumpers Appropriate jumpering chi...

Page 115: ...MODEL 1000 SEP 2005 INSTALLATION AND SETUP 3 61 Channel 1 I O Connector J6 Figure 3 23 Channel 1 I O Connector J6 ...

Page 116: ...SEP 2005 MODEL 1000 INSTALLATION AND SETUP 3 62 Channel 2 I O Connector J6 Figure 3 24 Channel 2 I O Connector J6 ...

Page 117: ...MODEL 1000 SEP 2005 INSTALLATION AND SETUP 3 63 Channel 3 I O Connector J3 Figure 3 25 Channel 3 I O Connector J3 ...

Page 118: ...SEP 2005 MODEL 1000 INSTALLATION AND SETUP 3 64 Channel 4 I O Connector J3 Figure 3 26 Channel 4 I O Connector J3 ...

Page 119: ...nix plug connections or bare wire connections GC Controller TB J5 COM1 J6 COM2 J10 COM3 and J11 COM4 Voltage 5 volts or 12 volts depending on jumper settings Recommended Maximum Cable Length 50 feet 15 meters Pinouts RS 232 Terminal Board for Field Wiring at Controller TB J5 COM1 J6 COM2 J10 COM3 or J11 COM4 Terminal 1 RLSD DCD OUT Terminal 2 S TxD IN Terminal 3 S RxD Terminal 4 DTR Terminal 5 GND...

Page 120: ...SETUP 3 66 RS 232 Terminal Board for Field Wiring at Controller TB P22 COM5 P23 COM6 P24 COM7 Terminal 1 N C OUT Terminal 2 S TxD IN Terminal 3 S RxD Terminal 4 DSR Terminal 5 GND Terminal 6 DTR Terminal 7 CST Terminal 8 RST Terminal 9 RI ...

Page 121: ...g at Controller TB P2 COM1 or P3 COM2 NOTE DB 9 plug on GC Controller is wired to eliminate the need for a null modem cable between the GC and a PC Terminal 1 RLSD DCD OUT Terminal 2 S TxD IN Terminal 3 S RxD Terminal 4 DTR Terminal 5 GND Terminal 6 DSR Terminal 7 RTS Terminal 8 CTS Terminal 9 RI ...

Page 122: ...at Controller TB P22 COM5 P23 COM6 P24 COM7 NOTE DB 9 plug on GC Controller is wired to eliminate the need for a null modem cable between the GC and a PC Terminal 1 N C OUT Terminal 2 S TxD IN Terminal 3 S RxD Terminal 4 DSR Terminal 5 GND Terminal 6 DTR Terminal 7 CTS Terminal 8 RTS Terminal 9 RI ...

Page 123: ...ons GC Controller TB J6 COM2 and J10 COM3 Voltage Line drivers meet Electronics Industries Association EIA specifications for RS 422 Recommended Maximum Cable Length 4000 feet 1219 meters Pinouts RS 422 Terminal Board for Field Wiring at Controller TB J6 COM2 Terminal 2 Tx Terminal 3 Tx Terminal 5 GND Terminal 6 Rx Terminal 7 Rx RS 422 continued Terminal Board for Field Wiring at Controller TB J10...

Page 124: ...rd for Field Wiring at Controller TB P3 COM2 Terminal 2 Tx Terminal 3 Tx Terminal 4 Rx Terminal 5 GND Terminal 8 Rx RS 422 continued Terminal Board for Field Wiring at Controller TB P22 COM5 P23 COM6 P24 COM7 Terminal 2 Tx Terminal 3 Tx Terminal 4 Rx Terminal 5 GND Terminal 8 Rx ...

Page 125: ...P23 COM6 P24 COM7 or Phoenix plug connections or bare wire connections GC Controller TB J5 COM1 J6 COM2 J10 COM3 and J11 COM4 for RS 485 Voltage Line drivers meet Electronics Industries Association EIA specifications for RS 485 Recommended Maximum Cable Length 4000 feet 1219 meters Pinouts RS 485 Terminal Board for Field Wiring at Controller TB J5 COM1 J6 COM2 or J10 COM3 J11 COM4 Terminal 2 RxTx ...

Page 126: ...P 2005 MODEL 1000 INSTALLATION AND SETUP 3 72 RS 485 continued Terminal Board for Field Wiring at Controller TB P2 COM1 or P3 COM2 P22 COM5 P23 COM6 P24 COM7 Terminal 2 RxTx Terminal 3 RxTx Terminal 5 GND ...

Page 127: ...CM 6117 supports a standard parallel printer port The parallel port connected via cable P N 3 2350 083 routes the signals from the CPU Board to the System Interface Board The parallel printer cable customer supplied is connected to J1 on the Field Termination Board Figure 3 27 Parallel Printer Port ...

Page 128: ...nterface The CPU LPM MCM 6117 supports I O expansion through the standard PC 104 Bus connectors at J19 and J20 The CPU supports both 8 bit and 16 bit PC 104 Bus modules The PC 104 Bus connector pin definitions are provided here for reference Figure 3 28 PC Bus Interface ...

Page 129: ...stems Disk OnChip DOC device as a Solid State Disk drive This section documents the required hardware configuration for the DiskOnChip device used for the GC The Silicon disk array is memory mapped into a 32K byte hole at segment E800H and has an I O control register at TECH Figure 3 29 Disk Configuration ...

Page 130: ...Jumpering for DOC mode with EPROM RAM or FLASH installed effectively acts to disable the Solid State Disk and similarly when a DOC device is installed and the jumper is selected for standard devices the DOC is disabled Device Type Selection Before using the M Systems the proper device type must be selected by correctly jumpering J11 The supported device type jumperings are shown here Figure 3 31 D...

Page 131: ...AND SETUP 3 77 3 4 4 14 Multi I O Connector Figure 3 32 Multi I O Connector The I O to the serial channels the printer port and keyboard are all terminated via the connector at J1 A cable P N 3 2350 083 plugs into the 50 pin connector ...

Page 132: ...117 utilizes the WinSystems WS16C48 ASIC high density I O chip mapped at a base address of 120H The first 24 lines are capable of fully latched event sensing with sense polarity being software programmable Two 50 pin connectors allow for easy mating with industry standard I O racks The pin out for the two connectors are shown in Figure 3 34 ...

Page 133: ...O Connectors The 48 lines of parallel I O are terminated through two 50 pin connectors at J7 and J4 The J7 connector handles I O ports 0 2 while J4 handles ports 3 5 The pin definitions for J7 and J4 are shown here Figure 3 34 Parallel I O Connectors J7 and J4 ...

Page 134: ...s to an I O rack or for miscellaneous purposes by jumpering J2 When J2 is jumpered 5 volts are provided at pin 49 of both J4 and J7 It the user s responsibility to limit current to a safe value less than 1A to avoid damaging the CPU Board The jumper definitions for J2 are shown here Figure 3 35 I O VCC Enable ...

Page 135: ...ed at the GC Controller Better control of printer output is available to the printer at the GC connected PC rather than at the GC Controller Note too that a printer connected to the GC Controller should not be operated in a hazardous environment SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Do not operate a standard off the shelf printer in a hazardous environment Failure to observe all safety precaut...

Page 136: ...B that is configured for RS 232 serial protocol a Leave at least one serial port available for connecting the GC Controller to a PC usually COM1 b Also leave available the other serial ports planned for use by RS 232 serial devices c See Section 3 4 4 for a complete listing of the TB s serial ports and their pinouts in order to prepare a serial printer cable 3 After the wiring connections have bee...

Page 137: ...s the GC Controller s Terminal Board for Field Wiring TB 2 Route digital I O lines appropriately Refer to drawing DE 20782 3 Make digital I O connections to the GC Controller TB There are connections for five digital input and five digital output lines as follows a Digital Inputs GC Controller TB connection ports J7 and J9 Digital Outputs GC Controller TB connection port J8 b For specific terminal...

Page 138: ...ure 3 36 a Jumper terminals 4 and 6 common on J7 b To enable digital input apply to terminal 5 on J7 either 12 or 24 volts DC 12 volts is DC available from the GC Controller s power supply by jumpering terminal 2 to terminal 5 see NOTE below and Figure 3 36 24 volts DC is not available from the GC Controller s power supply it must be obtained from an external power supply ...

Page 139: ...r that was built after March 1996 For high current digital output also install a special transient protection module TPM P N 3 2350 019 in TPM socket M8 Terminal Board for Field Wiring rear side of board See Appendix C this manual for TPM details Also move jumper JP1 on the System Interface Board CE 18118 from centered 12 V to centered 24 V and apply 24 VDC to J13 and J 14 on the rear side of the ...

Page 140: ...ler s Terminal Board for Field Wiring TB 2 Route analog I O lines appropriately Refer to drawing DE 20782 3 Make analog I O connections to the GC Controller TB In standard configuration there are connections for four analog input and two analog output lines as follows a Analog Inputs GC Controller TB connection port J12 Analog Outputs GC Controller TB connection port J14 b For specific pin number ...

Page 141: ...m Interface Driver board must be exchanged for one of these optional System Interface Boards allowing a quantity of either six or ten analog outputs see drawing CE 18118 Analog I O 6 analog outputs P N 3 2350 022 Analog I O 10 analog outputs P N 3 2350 023 If additional analog outputs are installed specific transient protection modules must also be installed on the GC Controller s Terminal Board f...

Page 142: ...ns could result in serious injury or death 1 Access the GC Controller s Terminal Board for Field Wiring TB a If necessary see instructions provided in Section 3 4 1 step 1 2 Locate the AC power connection terminal group on the TB It is labeled J21 and has three connection points labeled 1 HOT 2 NEU and 3 GND a Also see drawing DE 20782 in the GC Controller drawings addendum this manual 3 Connect A...

Page 143: ...or hazardous environments EQUIPMENT DAMAGE OR PERSONAL INJURY Do not apply AC electrical power to the Analyzer or the GC Controller until all electrical power interconnection and external signal connections have been verified and proper grounds have been made Failure to properly connect the GC unit may result in serious equipment damage or personal injury 4 If necessary connect the Controller s ch...

Page 144: ...to 110 psig 2 percent with the dual stage regulator at the gas cylinder 3 After 2 minutes shut the carrier gas bottle valve and observe the high side regulator gauge a The gauge should not bleed down more than 100 psig in 10 minutes b If helium is lost at a faster rate leaks are usually found between the helium bottle and the Analyzer Check and tighten all connections as well as the dual stage reg...

Page 145: ...grounds have been made Failure to verify all connections may result in equipment damage or personal injury Tubing should be clean and dry internally During installation use compressed air to remove moisture dust or other contaminants from all tubing To purge the carrier gas lines as preparation for first calibration follow these steps 1 Ensure that the MV vent line plug has been removed and the ve...

Page 146: ...SEP 2005 MODEL 1000 INSTALLATION AND SETUP 3 92 Figure 3 37 Analyzer Components ...

Page 147: ...ge regulator at the carrier gas bottle to adjust pressure Do not use the Carrier Pressure Adjust valve on the Flow Panel of the Analyzer to adjust carrier gas line pressure That valve is factory set and should not be adjusted 6 Allow the Analyzer system temperature to stabilize and the carrier gas lines to become fully purged with carrier gas a A period of 4 to 8 hours or overnight is recommended ...

Page 148: ...ck valve should be located on the SCS plate of the Analyzer 4 Fully open the metering valve on the Flow Panel below the rotameter 5 Access the upper enclosure of the Analyzer see Figure 3 42 to access the Valve Driver Board see Figure 3 44 6 On the Valve Driver Board upper enclosure set the Stream switch S2 to MAN if Stream 2 will be used for calibration gas 7 Open the calibration gas bottle valve...

Page 149: ...late the flow through the rotameter to approximately 50 cubic centimeters per minute cc min by adjusting the metering valve on the Flow Panel 14 Prepare for normal operation as follows a On the Valve Driver Board upper enclosure reset the Stream switch S2 to AUTO if Stream 2 will be used for calibration gas b Close upper enclosure ...

Page 150: ... GC System in Single Stream mode a To operate the GC System with a PC and the software MON2000 refer to the MON2000 Software for Gas Chromatographs User Manual P N 3 9000 522 or b To operate the GC System from the front panel keyboard and LCD refer to Section 4 Operation this manual For process GC systems that handle multiple streams and are equipped with optional purge system components you must ...

Page 151: ...anual P N 3 9000 522 or The GC Controller s built in keypad and Liquid Crystal Display LCD This offers only essential startup and operation functions but is useful in a hazardous environment or if no PC is available See Figure 4 1 When the unit has the COM4A Board installed COM8 is used for the display keyboard However if the unit does not have the COM4A Board installed the display keyboard uses C...

Page 152: ...cators 4 1 1 Liquid Crystal Display LCD 4 1 2 Keypad 4 1 3 Logging On to View or Edit Data See Section 4 2 First Time Log On 4 2 1 Subsequent Log On 4 2 2 Start Halt an Auto Sequence Analysis 4 2 3 Editing Procedures 4 2 4 Validity Checks of Data Entries 4 2 5 Local Display Menus See Section 4 3 Main Menu 4 3 1 Hardware Menu 4 3 2 Operator Entries Menu 4 3 3 Alarms Menu 4 3 4 Chromatogram Menu 4 3...

Page 153: ...ypad see Figure 4 1 4 1 1 Light Emitting Diode LED Indicators There are three colored status indicators on the GC Controller that show the gross status of the total system Table 4 1 summarizes the conditions indicated when these indicators are illuminated Table 4 1 Conditions indicated by the GC Controller s LED status indicator lights YELLOW The GC has an unacknowledged alarm s GREEN The Controll...

Page 154: ...ighting To log out if the Main Menu screen is displayed Press the ESC key 4 1 3 Keypad The front panel keypad on the Controller is arranged so that the most used keys may be pressed directly These are the numeric keys the ESC NEXT BKSP ENTER period and 8 9 keys The other keys are obtained by pressing ALT and the desired letter or symbol on the lower half of the key For instance to obtain capital A...

Page 155: ...u and saves the current values A pop up screen will ask if changes should be saved YES or NO Up Arrow 8 Causes a move up one field and saves the current value Down Arrow 9 Causes a move down one field and saves the current value Left Arrow ALT 7 Causes a move left one space and saves the current value Right Arrow ALT 6 Causes a move right one space and saves the current value Next NEXT Goes forwar...

Page 156: ... at the cursor position ALT and DEL keys Space SPACE Adds a space or is used to toggle lists ALT and SPACE keys Lower Function ALT Shifts the keys marked with a lower function legend into normal mode for data entering monitoring operation requirements Use by pressing ALT and the desired function key Alphabet Press and hold ALT key with any desired letter of the alphabet Upper case letters are ente...

Page 157: ... GC unit enter the USERNAME EMERSON To enter the username EMERSON 1 Type in E Press and hold down the key press the key twice then release the key 2 Type in M Press and hold down the key press the key once then release the key 3 Type in E Press and hold down the key press the key twice then release the key 4 Type in R Press and hold down the key press the key three times then release the key 5 Typ...

Page 158: ... 1 Idle Stream 0 Run 0 Anly 235 Cyc 240 Enter PIN x MON2000 May 16 07 09 10 1994 Alarm unackd Figure 4 3 Press the ENTER key then enter Username PIN If the Enter PIN x prompt does not remain displayed after you pressed the ENTER key press the ESC key and then press the ENTER key again 3 Enter your Username and Personal Identification Number PIN if necessary and then press the ENTER key If you have...

Page 159: ...through the sample loop for 60 seconds prior to the beginning of the first analysis cycle 4 At the Write Changes prompt press the ENTER key to accept the default Yes option Or to return to the GC Control submenu without beginning an auto sequence analysis press the ESC key 5 The green LED indicator will illuminate to show the GC is running an analysis To see the progress of analysis runs press the...

Page 160: ... submenu without halting analysis runs press the ESC key When analysis runs are halted at the end of the current analysis cycle the green LED indicator will no longer be illuminated If you choose Stop Now instead of Halt it forces the system to an immediate idle This may allow components to continue to elute from the columns Therefore it is recommended you choose Halt instead of Stop Now A Halt co...

Page 161: ...tree with the submenus branching for their particular functions 4 Return to initial screen Exit the editing procedure and save your changes by pressing the ESC key as many times as necessary to return to the initial screen 5 Save changes After editing changes are completed press the ENTER or ESC key The query Write Changes will appear Toggle the SPACE key to answer yes or no Press the ESC key to s...

Page 162: ...t attempt to edit or stop the Controller during a calibration sequence Calibration errors may result 10 Get out of screen saver mode To get out of the screen saver mode press any key on the keypad No keys pressed during one hour will activate screen saver mode 11 Match entered data with Data ID Tag When entering data a data identification tag will appear to the right of the data box on the display...

Page 163: ...rt of the application software The range requirements are described as part of the individual parameter description Data identification tags will appear to the right of any data box on the display to indicate the type of entry expected These identification tags will help you make valid entries Data identification tags and the corresponding valid entries are as follows s b I l f d t m q x string si...

Page 164: ...rete Inputs 5 Discrete Outputs 6 Valves 7 Current GRI Values 2 Operator Entries 1 Components 2 Timed Events 3 Analysis Cycle Time 4 System 5 Calculation Control 6 User Defined 3 Alarms 1 Limit Alarms 2 Discrete Alarms 3 Active Alarms 4 Unackd Alarms 4 Chromatogram 1 Live 5 GC Control 1 Auto 2 Single Stream 3 Calibration 4 Halt 5 Stop Now 6 Data Records 1 Raw Data 2 Raw Data 2 3 Raw Data 3 4 Analys...

Page 165: ...cords Config Rpt Maint Log 4 3 2 Hardware Menu The various submenus of the HARDWARE menu allow an oprator to define the stream functions analog inputs outputs discrete inputs outputs adjust the scales and range of the inputs outputs within limits set the valves and view the Gain Ratio Indicators GRI from the Analyzer Hardware 1 Streams 2 Analog Inputs 3 4 5 6 7 Analog Outputs Discrete Inputs Discr...

Page 166: ...be used to adjust or define timed events analysis and cycle times for sample streams designate system names and define the calculations desired Names or labels can be specified for data that may be desired for the various reports These submenus allow the operator to refine and customize the applications for the desired usage Operator Entries 1 Component Data 2 3 4 5 6 Timed Events Analysis Cycle T...

Page 167: ...to stop calibrate or place on automatic control a sample stream from the Analyzer This may occur a number of times while modifying inputs in the OPERATOR INPUTS menu Entering HALT will allow the Analyzer to finish the presently running operating sequence Entering STOP NOW orders the Analyzer to stop immediately and may require that some parameters be reentered In most cases the GC Control menu wil...

Page 168: ...nance personnel to review the operation of the GC System and often head off incipient problems Data Records 1 Raw Data 2 3 4 5 6 Raw Data 2 Raw Data 3 Analysis Cal Results Stream Data 4 3 8 Config Rpt Maint Log Menu The MAINTENANCE LOG menu allows the operator or maintenance personnel to view historical maintenance actions add any pertinent maintenance entries into the log and or change entries as...

Page 169: ...olumns 5 3 2 Precautions for Handling Printed Circuit Assemblies See Section 5 4 Service Troubleshooting and Repair Instructions See Section 5 5 Preamplifier 5 5 1 Temperature Control 5 5 2 Decoder 5 5 3 Fuse Replacement 5 5 3 1 Instructions for Removing the Decoder Board 5 5 3 2 Instructions for Reinstalling the Decoder Board 5 5 3 3 Analyzer Troubleshooting Guide 5 5 4 Flow Balance Check 5 5 4 1...

Page 170: ...tput Dialog Description 5 8 1 Changing a Variable 5 8 2 Changing the Bargraph 5 8 3 Performing a Manual Calibration 5 8 4 Performing an Automated Calibration 5 8 5 Analog Loopback Test Circuits 5 8 6 Upgrading Analog Outputs 5 8 7 Discrete Digital Inputs and Outputs See Section 5 9 Digital Loopback Test Circuit 5 9 1 Fuse Protection See Section 5 10 Analyzer Controller Interconnect See Section 5 1...

Page 171: ...necessary See next page This gives you a historical record of the operation of your Analyzer enables a maintenance technician to schedule replacement of gas cylinders at a convenient time and allows quick troubleshooting and repair when it becomes necessary A chromatogram a configuration report and a raw data report should also be made and filed with the checklist furnishing a positive dated recor...

Page 172: ...85 psig SAMPLE SYSTEM Sample Line Pressure s 1 ___ psig ____ psig 20 psig 2 ___ psig ____ psig 20 psig 3 ___ psig 4 ___ psig 5 ___ psig ____ psig ____ psig ____ psig 20 psig 20 psig 20 psig Sample Flows Rotameter 1 ___ cc min ____ cc min 40 60 cc 2 ___ cc min ____ cc min 40 60 cc 3 ___ cc min ____ cc min 40 60 cc Calibration Gas 4 ___ cc min 5 ___ cc min ____ cc min ____ cc min 40 60 cc 40 60 cc H...

Page 173: ... PC with the MON2000 software c Check the printer paper roll if used to ensure that a sufficient supply of paper remains Check carrier and calibration gas supplies d There is no routine maintenance to be performed on the GC Controller 5 2 3 Contract Service Emerson Process Management offers maintenance service programs that are tailored to fit specific requirements Contracts for service and repair...

Page 174: ...es are contained inside an explosion proof housing accessible by removing a threaded cover plate from the housing front See Figure 5 1 SERIOUS PERSONAL INJURY OR DEATH POSSIBLE The upper purged enclosure should not be opened when the unit is exposed to an explosive environment If access to the upper purged enclosure is required precautions must be taken to ensure that an explosive environment is n...

Page 175: ...rature controller valve driver and the preamplifier printed circuit assembly 5 3 2 Detector Elements Heater Elements Valves and Columns The detector elements heater elements valves and columns are located in the middle or oven section of the Analyzer The detector elements are located in the explosion proof housing inside the middle oven section of the Analyzer To gain access to the detector elemen...

Page 176: ...s Do not install or remove the Model 1000 Analyzer printed circuit assemblies or the GC Controller printed circuit assemblies while power is applied to the units Keep electrical components and assemblies in their protective conductive carriers or wrapping until ready for use Use the protective carrier as a glove when installing or removing printed circuit assemblies Maintain contact with a grounde...

Page 177: ...p 2 ROM Checksum Failure Disk on Chip 3 RAM Diagnostics Failure Bad RAM 4 Preamp Input 1 Out of Range Carrier gas Helium gone air not purged from carrier lines power failure bad thermistors preamp out of balance or failed Analyzer temperature interconnection wiring control power supplies 5 Preamp Input 2 Out of Range Same as number 4 6 Preamp Input 3 Out of Range Same as number 4 7 Preamp Input 4 ...

Page 178: ...e as number 19 26 Analog Output 8 Low Same as number 19 27 Analog Output 9 Low Same as number 19 28 Analog Output 10 Low Same as number 19 29 Analyzer Failure Carrier gas low below 105 PSIG at bottle or gone bad solenoid carrier gas leak in system 30 Power Failure The GC Controller has experienced a re start since alarms were last cleared caused by power failure Automatically starts in RUN mode an...

Page 179: ... Decoder 5 5 3 1 Fuse Replacement The Decoder Board is protected by a 3A 120VAC Picofuse which is installed in line on the neutral A C connection to the board The fuse is located above the power strip in the lower right corner of the Decoder Board and is replaced by unsoldering the bad fuse from the printed circuit board PCB and installing a new fuse Use a low power soldering iron 5 5 3 2 Instruct...

Page 180: ...late was mounted 5 Disconnect the three power leads from the terminal strip TB1 in the lower right corner of the Decoder Board 6 Disconnect the brown connectors at the top Grasp each connector by its top and bottom side and depress to release the hold down catch Only a small pressure is required but the connector must be fully engaged for the latch to release Pull the connector with a left right u...

Page 181: ... Decoder Board proceed as follows 1 Position the decoder board on the four standoffs 2 Tighten the four captive screws to secure the board in place 3 Attach the wires and plugs that were disconnected while removing the Decoder Board 4 Mount the two nylon spacers on the mounting studs near the center top and bottom of the Decoder Board 5 Reinstall the two printed circuit boards such that the compon...

Page 182: ... your problem immediately The following is a guide for troubleshooting if a problem with sample analysis occurs Table 5 2 is a Troubleshooting Checklist to obtain data for a problem diagnosis This data will be useful if it becomes necessary to call the Daniel Measurement Services DMS a division of Emerson Process Management for assistance 5 5 4 1 Flow Balance Check a Ensure that the flow panel gau...

Page 183: ...be due to one or more of the following 1 Programming of events 2 Contamination of valve sealing diaphragms by foreign matter 3 Improperly adjusted flows 4 Leaks in the carrier system 5 Column deterioration due to liquid contamination from a sample 6 Misidentifying peaks A noisy baseline can be caused by carrier leaks an electronic failure in the Preamplifier a faulty power supply or defective ther...

Page 184: ...mp balance voltage see par 5 5 6 _____ mV _____ mV 0 0 5 mV SAMPLE SYSTEM Leak check with SNOOP from sample probe to sample solenoid MODEL 1000 INPUTS GC 1 2 3 4 GRI 0 0 to 0 0 0 8 to 1 1 0 8 to 1 1 0 8 to 1 1 PAZ 12 bit AD 600 to 800 600 to 800 600 to 800 1150 to 1500 Value 12 bit AD 0 to 4095 0 to 4095 0 to 4095 0 to 4095 PAZ 16 bit AD 4800 to 6400 4800 to 6400 4800 to 6400 9200 to 12000 Value 1...

Page 185: ...aseline Check component values on report Number of peaks Retention times Date and file TEMPERATURE see par 5 5 7 Detector Temperature Thermocouple Wire 1 Type J C or ____ mV C or ____ mV 78 83 C Heater Block Temperature Thermocouple Wire 2 Type J Sample System Temperature if applicable C or ____ mV ____ C C or ____ mV ____ C 78 83 C MEASURE VENT FLOW see par 5 5 8 Analyzer Valve 3 ON ___ cc min __...

Page 186: ...to check for a drop in carrier pressure The drop should be less than 200 psig on the high side of the regulator gauge If the carrier pressure remains constant no leaks are present 5 Actuate the VALVE ON OFF switches and observe the pressure with the valves in different positions than in step 4 When the valves are switched some pressure change is normal because of carrier loss Momentarily open cyli...

Page 187: ...ecific zones of the Analyzer where a leak may occur 1 Plug the Measure Vent labeled MV vent line if it is open The SV or Sample Vent line should be left open or unplugged 2 Access the upper purged enclosure of the Analyzer so that you will be able to manually operate the analyzer valve switches located on the switch panel inside the box a See Figure 5 2 for an illustration of the Analyzer componen...

Page 188: ...SEP 2005 MODEL 1000 MAINTENANCE 5 20 Figure 5 2 Analyzer Components ...

Page 189: ...ck the carrier gas line first according to the steps that follow 3 Purge the Analyzer Valves with carrier gas as follows a Open the carrier gas bottle valve and slowly increase the carrier gas feed line pressure to 110 pounds per square inch gauge psig 2 with the dual stage regulator at the supply bottle ...

Page 190: ...e ON position b Open the carrier gas bottle valve and ensure that the carrier gas feed line pressure is 110 pounds per square inch gauge psig 2 c Shut the carrier gas supply bottle valve d Observe the pressure on the high side regulator gauge of the bottle Because the MV vent line is plugged the pressure should not decrease during a period of 2 3 minutes e Set all Analyzer Valve switches to the OF...

Page 191: ...s 8 This completes the calibration gas line leak check Next leak check the sample gas lines according to the steps that follow 9 Plug the SV vent line it may already be plugged if you performed steps 5 through 7 above to leak check the calibration gas line 10 Pressurize the sample gas line to 50 psig or a known pressure Sample gas line pressure of 50 psig is for leak check and test purposes only F...

Page 192: ...on gas bottle to the calibration gas line on the SCS mounting plate and reconnect the sample stream lines 5 5 4 5 Plugged Lines Columns or Valves To ensure that lines columns and valves are not plugged check the gas flow at valve ports For a reference use the flow diagram in the drawing package and remember these points about flow diagrams Port to port flow paths are indicated by solid or dashed l...

Page 193: ...alve follow these steps and refer to drawing CE 13021 or CE 20234 in the Analyzer drawings addendum of this manual 1 Remove the malfunctioning valve from the Analyzer Secure the valve in a vise clamping only at the baseplate 2 Loosen the torque bolt by turning counterclockwise 3 Remove the entire valve from the vise and prepare for disassembly in a clean area 4 Remove the torque bolt and disassemb...

Page 194: ...creen Then from the Control submenu press H to Halt MON2000 will ask you if you want to Halt the Analysis Select Yes and press the ENTER key 2 Open the door of the upper purged enclosure on the Analyzer 3 Refer to Figure 5 4 and attach the negative lead of a digital voltmeter to the black test point BRIDGE BALANCE Attach the positive lead of the digital voltmeter to the red test point BRIDGE BALAN...

Page 195: ...tor and Heater Block temperatures proceed as follows 1 Open the door of the upper purged enclosure 2 Next loosen and remove the four two thumb screws that hold the Valve Driver Board 3 Carefully edge the Valve Driver Board off the holding screws Do not disconnect the Valve Driver Board from the cable merely let the board rest face down secured by the cable 4 Locate the two Type J thermocouples The...

Page 196: ...or heater reading will be 5 cooler than the column heater with a wider temperature range fluctuation b Do NOT try to adjust these temperatures without consulting Daniel Measurement Services DMS The temperature control board is not field serviceable c If you determine that the temperature control board is bad return it to Daniel Measurement Services DMS for replacement 6 Replace the Valve Driver Bo...

Page 197: ...are shown in the following tables See also drawing DE 20782 in Addendum 2 GC Controller Drawings this manual Table 5 3 Analog Inputs to GC Controller from Analyzer Board Acronyms Terminal Board for Field Wiring at Controller TB DETECTOR PREAMPLIFIER SIGNAL OUTPUTS from ANALYZER TB J18 Terminal 11 common TB J18 Terminal 1 4 20 mA Gain channel 1 8x1 Measure between terminals 1 and 2 at TB J18 TB J18...

Page 198: ...s Board Acronyms Terminal Board for Field Wiring at Controller TB TB J12 Terminals 1 2 3 4 20 mA common shield Analog in 1 TB J12 Terminals 4 5 6 4 20 mA common shield Analog in 2 TB J12 Terminals 7 8 9 4 20 mA common shield Analog in 3 TB J12 Terminals 10 11 12 4 20 mA common shield Analog in 4 ...

Page 199: ...ters of the application with either a PC or the GC Controller s built in display and attempt to isolate or fix any incorrect parameters 5 6 1 GC Controller Access To access any of the GC Controller s electrical components perform all of the following steps 1 Ensure AC electrical power is disconnected from the unit and the environment is safe 2 Inside is the card cage holding the circuit boards The...

Page 200: ... cable necessary to obtain access to the desired board Remember or make note of the cable installation so the cables can be replaced in the same order Release the catch es and remove replace the circuit board s as necessary 5 Replace the card cage and tighten screws in the reverse order as the disassembly ...

Page 201: ...ion protocols are selected inside the GC Controller by changing jumpers These jumpers are normally specified by the customer at the factory If it becomes necessary to change the communications at the site access to the boards inside the enclosure is required to change the data interface chips The enclosure should not be opened when hazardous gases are present Refer to paragraph 5 6 1 if a communic...

Page 202: ... switch positions OFF 0 and ON 1 Refer to Section 3 4 1 for more dip switch settings 5 8 ANALOG INPUTS AND OUTPUTS The analog outputs can be calibrated adjusted using a PC with the MON2000 program software However the user output GC Controller analog outputs should be measured with a good digital meter upon initial installation at zero scale and full scale Then the span can be set with MON2000 sof...

Page 203: ...d double click on the appropriate cell or left click the mouse button and use the provided pull down menus When assigning analog outputs first check the CGM Analog Output Config field in the System dialog box see Section 5 1 An analog output assignment that uses the same analog output number as the CGM setting will produce erratic CGM trace output possibly with incorrect scaling See the following ...

Page 204: ...nt Value current readout values of the analog output values reflect scale assignments Zero Scale value used to represent the minimum value 4mA when scaling the analog output value Full Scale value used to represent the maximum value 20mA when scaling the analog output value Fixed Var analog output operation mode Fixed fixed Var variable If the operation mode is fixed the analog output is set to th...

Page 205: ...a calibration first to obtain accurate Zero and Full Adjustment values see Section 5 8 4 or Section 5 8 5 5 8 2 Changing a Variable To change a variable assignment click on the appropriate Variable cell Use the provided pull down menu and click on the desired variable to select it ...

Page 206: ...ysis data variables 1 To edit the variables and corresponding settings displayed by the bargraph click on the BARGRAPGH button or press the F5 key a The Bargraph dialog box appears b To edit the settings displayed double click on the appropriate cell or click and use the provided pull down menus See Section 5 8 1 for more details Multiple streams can be entered by separating the stream numbers wit...

Page 207: ... the appropriate Variable cell Use the provided pull down menu and click on the desired variable to select it 3 Click on the OK button to accept your changes and return to the Analog Outputs dialog box Click on the Cancel button to abort and return to the Analog Outputs dialog box ...

Page 208: ...Select the desired analog output by clicking anywhere in the corresponding row 4 Set the Zero Scale and Full Scale values as desired 5 Set the Fixed Var parameter to Fixed 6 Set Fixed Value equal to the Zero Scale value 7 Set Zero Adjustment and Full Adjustment to 0 0 Setting both adjustment values to 0 0 disables the scale adjustment 8 Click on the OK button to accept your changes and exit from t...

Page 209: ...e OK button to accept your changes and exit from the Analog Outputs dialog box 13 Return to the Analog Outputs dialog box Wait until the Current Value of the analog output is equal to the Full Scale value see Step 2 14 Record the value in engineering units read by the receiving device e g a voltmeter 15 Set Zero Adjustment to the value recorded in Step 8 16 Set Full Adjustment to the value recorde...

Page 210: ...to access this function 2 The Analog Outputs dialog box appears 3 Select the desired analog output by clicking anywhere in the corresponding row 4 Click on the AutoCal F8 button or press the F8 key You can abort this process at any time by clicking on the Cancel button 5 The Zero Scale Adjustment dialog box appears Current device value on engineering units Input the appropriate value and click on ...

Page 211: ...Scale Adjustment dialog box appears Current device value on engineering units Input the appropriate value and click on the OK button To prevent scale adjustment set both adjustment values to zero 0 0 7 If the values entered are within tolerance data in the zero and full adjustment columns is updated Otherwise MON2000 displays an error message ...

Page 212: ...NCE 5 44 Figure 5 6 Analog Loopback with Two Analog Outputs 5 8 6 Analog Loopback Test Circuits External loopback test circuits can be built for troubleshooting the GC System s analog input output operation See Figures 5 6 and 5 7 ...

Page 213: ...MODEL 1000 SEP 2005 MAINTENANCE 5 45 Figure 5 7 Analog Loopback with More Than Two Analog Outputs ...

Page 214: ...N 3 2350 022 Analog I O 10 analog outputs P N 3 2350 023 If additional analog outputs are installed specific transient protection modules must also be installed on the GC Controller s Terminal Board for Field Wiring TB For details about transient protection modules see Appendix C this manual Also see drawing CE 18115 sheet 2 in the GC Controller drawings addendum this manual Once the Analog Board ...

Page 215: ...UTS AND OUTPUTS For instructions on connecting digital inputs and outputs to the GC Controller see Section 3 4 6 and drawing DE 20782 GC Controller drawings addendum this manual 5 9 1 Digital Loopback Test Circuit An external loopback test circuit can be built for troubleshooting the GC System s digital input output operation See Figure 5 8 ...

Page 216: ...EATH POSSIBLE Before attempting to examine or replace the Controller s fuse disconnect AC power from the Controller Failure to observe all safety precautions could result in serious injury or death To locate and replace the Controller s fuse note the following Fuse Location Inside small black holder by lower left corner of the GC Controller TB by label F1 see Figure 5 9 Spare fuses are in a small ...

Page 217: ...ignal common these signals are as follows see also Section 3 3 and Table 3 2 this manual Four outputs from the Analyzer preamplifier 4 20 mA current loop These are the amplified electrical output from the Analyzer detector and bridge Function Code signals the Function Code Strobe and Auto Zero These signals are initialized at the GC Controller and interpreted at the Analyzer s decoder board in ord...

Page 218: ...SEP 2005 MODEL 1000 MAINTENANCE 5 50 Figure 5 10 Analyzer and GC Controller Interconnect Leads ...

Page 219: ... by the Analyzer s decoder board determines the position of specific chromatograph valves Chromatograph valve positions are either SET ON or RESET OFF Table 5 6 lists the voltage measurements that should occur at the Function Code terminals for corresponding states of the chromatograph valves A measurement of 5 five volts at any of the function code terminals indicates a binary zero 0 A measuremen...

Page 220: ...lts DC Valve 1 OFF 0 5 0 5 Valve 2 ON 5 0 0 5 Valve 2 OFF 0 0 0 5 Valve 3 ON 0 5 0 0 Valve 3 OFF 5 0 0 0 Valve 4 ON 5 5 5 5 Valve 4 OFF 0 5 5 5 Valve 5 ON 5 0 5 5 Valve 5 OFF 0 0 5 5 Stream 1 5 5 5 0 Stream 2 0 5 5 0 Stream 3 5 0 5 0 Stream 4 0 0 5 0 Stream 5 5 5 0 0 1 The Function Code Strobe measured at either the GC Controller TB J20 1 or the Analyzer TB4 15 occurs 1 one second or more followin...

Page 221: ... Analyzer Valve AV 4 1 AV 4 2 AV 5 3 AV 5 4 AV 1 5 AV 1 6 AV 2 7 AV 2 8 Stream Valve SV 1 SV 2 3 4 5 9 SV 2 SV 1 3 4 5 A SV 3 SV 1 2 4 5 B SV 4 SV 1 2 3 5 C SV 5 SV 1 2 3 4 D AV 3 E AV 3 F A measurement of 5 five volts at any of the function code terminals indicates a binary zero 0 A measurement of 0 zero volts indicates a binary one 1 ...

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Page 223: ...el Measurement Services DMS a division of Emerson Process Management offers service and repair service contracts that make maintaining most spares for the Model 1000 GC System unnecessary Details regarding Daniel Measurement Services contracts may be obtained by contacting the Daniel Measurement Services Service Department at the address or telephone number on the Customer Repair Report in the bac...

Page 224: ...000 369 1 1 ASCO 3 Way solenoid valve Auto Cal 4 5000 075 1 ASCO 3 Way solenoid repair kit 4 4000 213 1 1 G C valve repair kit 6 port valve 3 9300 108 3 1 Carrier gas regulator 4 9500 084 1 Temperature control thermistor 3 0500 103 1 Thermistor seal 6 5000 084 6 6 Thermistor set 9K 6 1611 083 1 1 Microfuse 3A 120VAC 5 4203 230 2 2 Inline filter element Nupro 4 5000 113 2 1 ...

Page 225: ...d No 5 3 2350 041 or 6 channel Analog I O board No 5 optional 3 2350 039 or 10 channel Analog I O board No 5 optional 3 2350 034 or System interface and driver board 3 2350 005 Passive termination board 3 2350 001 Transient suppressor modules optional PCA Quad Sngl 3 2350 002 PCA Quad DIFF 3 2350 003 PCA RS 232 Sngl 3 2350 027 PCA Hi Pwr Discrete Output 3 2350 019 LED display board 3 2350 026 ...

Page 226: ...EL 1000 RECOMMENDED SPARE PARTS 6 4 6 2 2 Electrical and Mechanical Components GC Controller Description Part Number Maximum Minimum 115 230 VAC power supply 3 2350 020 1 1 Fuse 250 VAC 2A 5 x 20 mm 5 4203 420 5 1 ...

Page 227: ...Guide Serial Communications Appendix A Manifold for Two Carrier Gas Bottles to GC System Appendix B Guide to Transient Protection Modules Appendix C Internal Modem for GC Controller Appendix D Setting Solenoid Purge Flows Appendix E 2350 to 2350A CPU Retrofit Instructions Appendix F ...

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Page 229: ... Serial Port and Cable Configurations for RS 232 See Section A 1 RS 232 Connection from GC Controller to PC See Section A 2 DB 9 Serial Port of GC to DB 9 Port of PC A 2 1 DB 9 Serial Port of GC to DB 25 Port of PC A 2 2 Phoenix Plug Port of GC to DB 9 Port of PC A 2 3 Phoenix Plug Port of GC to DB 25 Port of PC A 2 4 RS 232 Connection from GC Controller to External Modem See Section A 3 DB 9 Seri...

Page 230: ...GC Controller s Terminal Board for Field Wiring and the connection points for external devices are as follows Table A 1 Serial Ports on the Terminal Board for Field Wiring GC Controller DB 9 plug connection Phoenix plug bare wire connection Serial Port 1 COM1 P2 J5 Serial Port 2 COM2 P3 J6 Serial Port 3 COM3 J10 Serial Port 4 COM4 J11 Serial Port 5 COM5 P22 Serial Port 6 COM6 P23 Serial Port 7 COM...

Page 231: ...PC is Data Terminal Equipment or DTE See Section A 2 External modem to GC connections serial A custom serial cable must be built to emulate a null modem cable for a connection between the GC Controller and an external modem The modem is Data Communications Equipment or DCE See Section A 3 Both of the GC Controller s DB 9 jacks are female and have identical pin assignments NOTE A DB 9 male pin numb...

Page 232: ...y be able to use a straight through serial cable terminated as DB 9 male DB 9 female This will work if the PC has a male DB 9 serial port and its pin assignments are identical to those found on a typical DB 9 serial port of an IBM PC The necessary straight through serial cable can be obtained from most computer products suppliers so custom building a cable normally is not necessary Wiring and sign...

Page 233: ... to use a straight through serial cable terminated as DB 9 male DB 25 female This will work if the PC has a male DB 25 serial port and its pin assignments are identical to those found on an IBM PC The necessary straight through serial cable can be obtained from most computer products suppliers so custom building a cable normally is not necessary Wiring and signal path are illustrated as follows se...

Page 234: ...the Phoenix Plug serial ports of the GC and a PC with DB 9 serial port you will need to manufacture the cable and its DB 9 female plug cable end as illustrated below see Figure A 5 Figure A 5 GC Phoenix Plug Port to PC DB 9 Port The cable for this application is also available from P N 3 2350 068 in a customer specified length with six exposed leads and a female DB 9 plug ...

Page 235: ... to DB 25 Port of PC To make an RS 232 serial connection between one of the Phoenix Plug serial ports of the GC and a PC with DB 25 serial port you will need to manufacture the cable and its DB 25 female plug cable end as illustrated below see Figure A 6 Figure A 6 GC Phoenix Plug Port to PC DB 25 Port ...

Page 236: ... need to manufacture a cable The cable will need DB 9 male and DB 25 male plug cable ends as illustrated below see Figure A 7 The DB 9 jack on the GC serial port is wired to appear like a Data Communications Equipment DCE Therefore you use a custom null modem type cable as shown above to make the connection between the GC and an external modem GC serial ports were wired to appear as DCE so that a ...

Page 237: ...t of Modem To make an RS 232 serial connection between one of the Phoenix Plug serial ports of the GC and an external modem with DB 25 serial port you will need to manufacture the cable and its DB 25 male plug cable end as illustrated below see Figure A 8 Figure A 8 GC Phoenix Plug Port to External Modem DB 25 Port ...

Page 238: ...nterface between the RS 232 output of the PC and the RS 422 protocol needed for long distance serial input to the GC Specifics of the line driver are as follows Black Box brand Model LD485A MP RS 232 RS 485 Multipoint Line Driver RS 232 input to connect to the PC and RS 422 or RS 485 output to connect to the GC RS 422 line terminations are illustrated in Figure A 9 below and jumper and switch sett...

Page 239: ...AL Normal operation used instead of loopback testing DIP Switch Banks or Shunts XW1A DCE XW1B DTE XW1A DCE Sets line driver to operate as data communications equipment DCE S2 UNTERM No resistor network termination needed for one PC direct to one GC Jumper Positions W8 HALF Half duplex operation W9 ON No delay clear to send CTS always true W15 A B RS 485 driver enabled by request to send RTS W16 A ...

Page 240: ...al input to the GC Specifics of the line driver are as follows Black Box brand Model LD485A MP RS 232 RS 485 Multipoint Line Driver RS 232 input to connect to the PC and RS 422 or RS 485 output to connect to the GC RS 485 line terminations are illustrated in Figures A 10 and A 11 next page and jumper and switch settings to configure the line driver device are listed in Table A 3 NOTE For this exam...

Page 241: ...MODEL 1000 SEP 2005 SUPPLEMENTAL WIRING GUIDE SERIAL COMMUNICATIONS A 13 Figure A 10 Example RS 485 Serial Cable Terminations Line Driver to GC Controller COM3 ...

Page 242: ...DCE XW1B DTE XW1A DCE Sets line driver to operate as data communications equipment DCE S2 UNTERM No resistor network termination needed for one PC direct to one GC Jumper Positions W8 HALF Half duplex operation W9 0ms 0 zero milliseconds delay from time request to send RTS received as true until clear to send CTS asserted as true W15 A B RS 485 driver enabled by RTS W16 A B Half duplex turnaround ...

Page 243: ...rt number for the manifold is 3 5000 050 The benefits of this manifold are as follows When one bottle is nearly empty i e 100 psig remaining the other bottle becomes the primary supply Each bottle can be disconnected for refilling without interrupting GC operation The illustration and information in this Appendix are from drawing AE 10098 This Appendix is organized as follows Illustration See Sect...

Page 244: ...SEP 2005 MODEL 1000 MANIFOLD FOR TWO CARRIER GAS BOTTLES TO GC SYSTEM B 2 Figure B 1 Manifold for Two Carrier Gas Bottles to GC System B 1 ILLUSTRATION ...

Page 245: ...1 bleed valve and let the carrier gas bleed to atmosphere until both gauges read 0 psig then close V 1 7 Repeat steps 4 and 5 two more times to purge the line to V 2 8 Purge the line to V 3 by repeating steps 2 through 6 but this time use bleed valve V 4 and Carrier Cylinder 2 9 With valves 1 4 closed open both cylinder valves and regulate both carriers to approximately 10 psig 10 Open V 2 and V 3...

Page 246: ...zer run overnight before calibrating B 3 REPLACING CARRIER CYLINDER To replace one carrier cylinder without interrupting GC operation proceed as follows 1 Turn cylinder valve off 2 Back off on cylinder pressure regulator until handle turns freely Remove cylinder 3 Attach new cylinder to regulator and repeat steps 3 through 6 of Installation Instructions using appropriate bleed valve to purge line ...

Page 247: ...rom sources that affect the input output connections of the GC Controller This includes connections to stream switching systems analog and digital input output devices and serial communications devices The transient signals may be caused by the devices themselves or by environmental conditions that induce signals through the input output cabling Additionally the GC Controller was designed to compl...

Page 248: ...anual There may be times when it is more appropriate to change inspect diagnose or service the individual TPMs rather than the entire Terminal Board TB Consequently this section of the Appendix provides a guide to the individual TPMs installed on the TB their uses and their part numbers see Table C 1 following page Further Explanation Individually the TPMs can be divided into two main categories d...

Page 249: ...ER INTERCONNECT 3 2350 002 3 2350 003 Quad Sngl Tnst M9 Fnct codes M15 FC Strobe A Zero Alarm M1 Pre AMP Angl s STREAM SWITCH 3 2350 002 Quad Sngl Tnst M16 Sol 1 4 M10 Sol 5 8 in DIGITAL I O LOW CURRENT 3 2350 002 Quad Sngl Tnst M5 D 1 in M14 D 2 5 out M5 D 5 NOTES 16 pin out DIGITAL I O LOW CURRENT 3 2350 003 Quad Diff Tnst M8 D 1 4 in ANALOG I O 3 2350 003 Quad Diff Tnst M1 A 1 4 in M13 A 5 8 ou...

Page 250: ... O low current VISUAL INSPECTION MOVs M1 M4 Good Blue in color Failed Discolored to brown or black Resistors R1 R4 Good Intact Failed Broken or open EQUIPMENT DAMAGE Remove transient protection module from board before all ohmmeter checks Failure to do so may cause equipment damage OHMMETER CHECK MOVs M1 M4 Good Open or infinite ohms Failed Shorted or 0 zero ohms Resistors R1 R4 Good 330 ohms Fail...

Page 251: ...s R1 R8 Good Intact Failed Broken or open EQUIPMENT DAMAGE Remove transient protection module from board before all ohmmeter checks Failure to do so may cause equipment damage OHMMETER CHECK MOVs M1 M8 Good Open or infinite ohms Failed Shorted or 0 zero ohms Resistors R1 R8 Good 150 ohms Failed Open infinite ohms or short 0 ohms Diodes Z1 Z4 Good Open infinite ohms in one direction and 4 12 megohm...

Page 252: ...esistors R1 R8 Good Intact Failed Broken or open EQUIPMENT DAMAGE Remove transient protection module from board before all ohmmeter checks Failure to do so may cause equipment damage OHMMETER CHECK MOVs M1 M8 Good Open or infinite ohms Failed Shorted or 0 zero ohms Resistors R1 R8 Good 150 ohms NOT CONFIRMED IN LAB Failed Open infinite ohms or short 0 ohms Diodes Z1 Z4 Good Open infinite ohms in b...

Page 253: ...or black Resistors R1 R4 Good Intact Failed Broken or open EQUIPMENT DAMAGE Remove transient protection module from board before all ohmmeter checks Failure to do so may cause equipment damage OHMMETER CHECK MOVs M1 M4 Good Open or infinite ohms Failed Shorted or 0 zero ohms Resistors R1 R4 Good 330 ohms Failed Open infinite ohms or short 0 ohms Diodes Z1 Z4 Good Open infinite ohms in both directi...

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Page 255: ...from the GC Controller SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Before opening the door to the upper purged enclosure of the Model 1000 make certain the power supply switch is OFF and the AC power cord is disconnected Failure to observe all safety precautions could result in serious injury or death 3 Remove the cover from the GC Controller housing to expose the GC Controller s Terminal Board for ...

Page 256: ...jack at the back edge of the GC Internal Modem card 9 Reconnect all ribbon cable plugs that were disconnected in step 8 above 10 Return and secure the Card Cage Assembly in its chassis mounting Tighten the four screws 11 Return and secure the GC Controller s Terminal Board for Field Wiring in its original position Hand tighten the six screws 12 Restore AC power to the 2350A GC Controller 13 Connec...

Page 257: ...treams in which the makeup of the different analysis streams may differ significantly from stream to stream For process GC systems with multiple streams a solenoid purge setup is necessary before starting normal GC operation A solenoid purge check as outlined below is also recommended as part of a regular GC system maintenance schedule to be performed for example once every month The steps in this...

Page 258: ...the normally open NO port of each stream solenoid a Refer to the sample system drawing for the location of these valves 4 Access the Analyzer Valve Driver Board s with stream switches Manually turn the switch for stream 1 ON and turn all other streams OFF 5 Open the purge valve associated with stream 2 and regulate the flow through the solenoid purge flow indicator to approximately 200 cubic centi...

Page 259: ... Board b Next open the solenoid purge valve associated with stream 1 to add 200 ccm to the current flow as measured at the solenoid purge flow indicator 9 When all flows have been set return all stream switches to AUTO positions at the Analyzer Valve Driver Board 10 After you have set all stream switches to AUTO positions close the upper purged enclosure that houses the Analyzer Valve Driver Board...

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Page 261: ...may be upgraded in the field through the MON2000 Software refer to the MON2000 Software for Gas Chromatographs User Manual P N 3 9000 522 for BOS upgrade details Optional boards may be plugged directly into the PC 104 Bus connectors J19 and J20 on the CPU Board assembly The COM4A Board provides four additional serial ports COM5 through COM8 A Modem Board and or Ethernet Board may be also be plugge...

Page 262: ...wer cord is disconnected Observe all safety precautions when you are working in a hazardous environment Failure to observe all safety precautions could result in serious injury or death a For the purged Controller the front panel is secured by 16 screws Remove those screws first b Then carefully lower the front panel on its bottom hinges The front panel is heavy so make sure it does not drop and c...

Page 263: ... connected to the System Interface Board P N 3 2350 005 P N 3 2350 022 or P N 3 2350 023 8 Remove the I O48 board assembly drawing BE 12973 and cables from the top slot of the cage card assembly This board is not used on the 2350A GC Controller 9 Remove the CPU Board assembly drawing CE 19281 and cables from the second slot of the card cage assembly This board is not used on the 2350A GC Controlle...

Page 264: ...ect or change the GC Controller s COM ID setup at the GC Controller site locate the DIP switch as described in the following steps SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Before removing the unit cover from the GC Controller make certain the power supply switch is OFF and the AC power cord is disconnected Observe all safety precautions when you are working in a hazardous environment Failure to o...

Page 265: ...el is secured by 16 screws Remove those screws first a Then carefully lower the front panel on its bottom hinges The front panel is heavy so make sure it does not drop and cause damage The DIP switch is located on the lower left side of the front panel see Figure F 2 Figure F 2 Purged Controller DIP Switch ...

Page 266: ...emove the access panel on the right side of the card cage assembly see Figure F 3 Figure F 3 Right Side View of Rack Mount and Panel Mount Controllers 18 Inspect or change the DIP switch settings as necessary a See Table F 1 as a guide b Make sure you record in the GC Controller s maintenance records any changes you make to the switch settings ...

Page 267: ...M ID or Device ID O Switch number 1 is the least significant bit and switch number 5 is the most significant bit O Switch to ON 1 Switch to OFF 0 O Switch 6 is a spare for future use Switches 7 and 8 are set as needed for the presence of an optional LOI Local Operator Interface connected via COM8 When the COM4A Board is installed If the COM4A Board is not installed the LOI is connected via COM4 ...

Page 268: ...s Switch Positions COM ID 1 2 3 4 5 1 ON OFF OFF OFF OFF 2 OFF ON OFF OFF OFF 3 ON ON OFF OFF OFF 4 OFF OFF ON OFF OFF 5 ON OFF ON OFF OFF 6 OFF ON ON OFF OFF 7 ON ON ON OFF OFF 8 OFF OFF OFF ON OFF RAM CLEAR Dip Switch Setting Switch Positions 8 Clears RAM when unit powered down ON Keeps RAM when unit powered down OFF ...

Page 269: ...e Board J8 and J10 This provides access to COM3 on J10 and COM4 on J11 of the Field Termination Board The serial port setup in the MON2000 Software for COM4 must be selected as a PC port e For a system WITH a keyboard and display connect cable P N 3 2350 087 from CPU J6 to the System Interface J8 and J12 This provides access to COM3 on J10 and COM4 is dedicated for use as a serial interface to the...

Page 270: ...included with the upgrade kit on the instruction decal located on the inside right wall of the purged units or on the card cage of the rack or panel mount units Figure F 5a MON2000 Serial Port 8 Front Panel Configuration with COM4A Board Installed Figure F 5b MON2000 Serial Port 4 Front Panel Configuration ...

Page 271: ...the purged Controller the front panel is secured by 16 screws Remove those screws first b Then carefully lower the front panel on its bottom hinges The front panel is heavy so make sure it does not drop and cause damage c For the rack mount Controller the rear of the enclosure is open it allows access for most field wiring procedures without removing the enclosure 2 Locate the GC Controller s Term...

Page 272: ...n the Field Termination Board via cable P N 3 2350 085 to J6 on COM4A d Connect COM7 P24 on the Field Termination Board and COM8 via cable P N 3 2350 086 to J3 on COM4A e Install the CPU assembly into the third slot of card cage Connect the CPU cables as detailed in Section 6 3 Basic 2350A Configuration f Install the DB9 connector from COM5 to P22 on the Field Termination Board with jackpost assem...

Page 273: ...l Port 8 is usually assigned via MON2000 Application Serial Ports menu path Select Front Panel from the Usage pull down menu see Figure F 6a and F 5b below Figure F 6a MON2000 Serial Port 8 Front Panel Configuration with COM4A Board Installed Figure F 6b MON2000 Serial Port 4 Front Panel Configuration ...

Page 274: ...el is heavy so make sure it does not drop and cause damage c For the rack mount Controller the rear of the enclosure is open it allows access for most field wiring procedures without removing the enclosure 2 Locate the GC Controller s Terminal Board for Field Wiring TB The TB is attached to the GC Controller s card cage assembly facing the enclosure s front panel In the rack mount Controller the T...

Page 275: ...0 PC 104 Bus connector on the CPU assembly If an option board is already plugged into the PC 104 bus on the CPU the modem and mounting hardware will be installed into the PC 104 connector on the option board Figure F 7 Modem c Plug one end of the modem extension cable P N 3 2350 075 into J1 of the modem assembly The in line jack on the remaining end of the modem extension cable attaches to the low...

Page 276: ...IONS F 16 Jumper Pin J4 J5 Open J6 3 5 4 6 J7 7 8 J9 Open 7 To use an existing Modem 1414 a For operation with the 2350A CPU set the Standard 1414 Modem jumpers per the following table Table F 2 Modem Jumpers b On the 2350A WinSystems CPU set J21 pin 13 14 ...

Page 277: ...t panel is heavy so make sure it does not drop and cause damage c For the rack mount Controller the rear of the enclosure is open it allows access for most field wiring procedures without removing the enclosure 2 Locate the GC Controller s Terminal Board for Field Wiring TB The TB is attached to the GC Controller s card cage assembly facing the enclosure s front panel In the rack mount Controller ...

Page 278: ...C 104 Bus on the CPU install the Ethernet assembly and mounting hardware into the PC 104 Bus connector on the option board c Plug one end of the Ethernet extension cable P N 3 2350 088 into J5 of the Ethernet assembly The in line jack on the remaining end of the Ethernet extension cable attaches to the lower left inside wall of the card cage shield after the CPU assembly is reinstalled and all cab...

Page 279: ...d is installed on the PC 104 Bus on the CPU install the Ethernet Board and mounting hardware on the PC 104 Bus connector on the option board If you are using the CSA approved Radicom modem ensure that it is the top card in the card cage assembly The connection configuration of the Radicom modem requires installation at the top of the assembly ...

Page 280: ...SEP 2005 MODEL 1000 2350 to 2350A CPU RETROFIT INSTRUCTIONS F 20 This page intentionally left blank ...

Page 281: ...ith 120 Bypass CE 16320 S C S Plate 3 Streams CE 16420 S C S Plate 4 Streams BE 17204 Flow Configuration Backflush to Measure Dual Column w SSO DE 18567 Wiring Model 1000 FPD GC with Model 2350A SCS Oven and Sample Pump DE 18578 Wiring Diagram Model 1000 GC Integral 2350A One Det One Carr S C S PLT and Cyclops Z Purge DE 18579 Analyzer Wiring Diagram F I D GC w Integral 2350A Remote S C S Oven CE ...

Page 282: ...SEP 2005 MODEL 1000 ANALYZER DRAWINGS Addendum 1 2 This page intentionally left blank ...

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Page 297: ...de Sheet 2 of 2 Solder Side Descript Transient Protect Mod Plugs CE 18118 System Interface and Driver Board CE 20765 Assembly CPU Board Sheets 1 2 CE 20766 Assembly COM4A Serial Board Sheets 1 2 BE 20767 Assembly Modem Board DE 20775 Assembly GC Controller Sheet 5 of 5 Card Cage Detail DE 20778 Dimensional GC Controller 19 Rack w Display Keypad DE 20779 Dimensional GC Controller Explosion Proof Un...

Page 298: ...SEP 2005 MODEL 1000 GC CONTROLLER DRAWINGS Addendum 2 2 Block Diagram of GC Controller Circuit Boards ...

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Page 315: ...e the nearest DMS office sales or service center call 713 827 6314 Fax 713 827 6312 write to Daniel Measurement Services a division of Emerson Process Management 11100 Brittmoore Park Drive Houston Texas 77041 Or contact DMS via the following site www emersonprocess com daniel 4 When contacting DMS for product service the Purchaser is asked to provide information as indicated on the following page...

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Page 317: ...EQUIPMENT MODEL S N FAILURE DATE DESCRIPTION OF PROBLEM WHAT WAS HAPPENING AT TIME OF FAILURE ADDITIONAL COMMENTS REPORT PREPARED BY TITLE IF YOU REQUIRE TECHNICAL ASSISTANCE PLEASE FAX OR WRITE THE CUSTOMER SERVICE DEPARTMENT AT DANIEL MEASUREMENT SERVICES DIVISION OF EMERSON PROCESS MANAGEMENT PHONE 713 827 6314 ATTN CUSTOMER SERVICE FAX 713 827 6312 11100 BRITTMOORE PARK DRIVE HOUSTON TEXAS 770...

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Page 320: ...alytical Inc Divisions of Emerson Process Management reserve the right to make changes to any of its products or services at any time without prior notification in order to improve that product or service and to supply the best product or service possible www emersonprocess com daniel ...

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