Emerson Rosemount Analytical CAT 100 Instruction Manual Download Page 104

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Instruction Manual

748441-D
April 2002

5-36 Maintenance and Service

Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

Plug Locations on OXS PCB

Pin-base P2

Oxygen sensor

Cable P1, 5

pin connector BKS
PCB, X5 (sensor
signal)

Cable P1, 2

pin connector BKS
PCB, X7 (tempera-
ture sensor (not
used in combina-
tion with infrared
measurement)

Figure 5-25. OXS PCB Plug Locations

Summary of Contents for Rosemount Analytical CAT 100

Page 1: ...Instruction Manual 748441 D May 2004 http www processanalytic com Model CAT 100 Continuous Analyzer Transmitter ...

Page 2: ...cautions and instructions marked on and supplied with the product Inform and educate your personnel in the proper installation operation and mainte nance of the product Install your equipment as specified in the Installation Instructions of the appropriate In struction Manual and per applicable local and national codes Connect all products to the proper electrical and pressure sources To ensure pr...

Page 3: ...c Oxygen Method 1 6 c Electrochemical Oxygen Method 1 7 d Thermal Conductivity Method 1 9 1 4 Specifications 1 11 a General 1 11 b CAT 100 Detector 1 12 2 0 INSTALLATION 2 1 2 1 Process and Calibration Gas Connection 2 1 a Gas Conditioning 2 5 2 2 Installation 2 6 a Location 2 6 b Limitations 2 6 c Gas Lines 2 6 d Services 2 6 e Mounting Options 2 6 f Vent Lines 2 6 g Electrical Connections 2 7 2 ...

Page 4: ...ration 3 12 a Zeroing 3 12 b Spanning 3 12 3 5 Manual Calibration 3 13 a Zeroing 3 13 b Spanning 3 13 3 6 Automatic Calibration Option 3 15 a Zeroing 3 15 b Combined Zeroing and Spanning 3 15 3 7 Concentration Limits 3 16 3 8 Measurement 3 17 3 9 Shut Down 3 18 3 10 Temperature Stabilization option 3 19 a Changing Temperature Settings 3 19 b Controller Settings 3 20 4 0 SERIAL INTERFACE OPTION 4 1...

Page 5: ...of the Analyzer 5 16 c Cleaning and Replacement of Photometric Components 5 17 d Light Source Replacement 5 18 e Removal of Analysis Cells 5 19 f Cleaning of Analysis Cells and Windows 5 20 g Reinstalling Analysis Cells 5 20 h Reinstalling Photometer Assembly 5 20 i Physical Zeroing 5 20 j Replacement of Electrochemical Oxygen Sensor 5 21 k Check of the Sensor 5 22 l Removal of the Sensor 5 23 m B...

Page 6: ...Infrared Channel Oxygen Measurement Combined 5 5 Figure 5 3 Analyzer Component Layout 1 Channel Oxygen Measurement Electrochemical 5 6 Figure 5 4 Analyzer Component Layout Paramagnetic Oxygen Measurement Thermal Conductivity Combined 5 7 Figure 5 5 Analyzer Component Layout Infrared Channel Thermal Conductivity Combined 5 8 Figure 5 6 Photometer Assembly with Pyroelectrical Detector 5 10 Figure 5 ...

Page 7: ...l Assignments 2 8 Table 2 3 Optional Status Signals Terminal Assignments 2 8 Table 2 4 Optional Cross Compensation Analog Inputs 2 8 Table 2 5 Optional RS232 485 Terminal Assignments 2 9 Table 2 6 Power Connections Terminal Assignments 2 9 LIST OF DRAWINGS Located In Rear Of Manual 659921 Assembly Drawing CAT 100 660198 Wiring Diagram CAT 100 660210 Installation Drawing CAT 100 660371 Diagram Powe...

Page 8: ...Instruction Manual 748441 D April 2002 vi Contents Rosemount Analytical Inc A Division of Emerson Process Management Model CAT 100 ...

Page 9: ...ollowing definitions apply to DANGERS WARNINGS CAUTIONS and NOTES found throughout this publication DANGER Highlights the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored WARNING Highlights an operation or maintenance procedure practice condition statement etc If not strictly observed could result in injury death or long te...

Page 10: ...ed AUTHORIZED PERSONNEL To avoid explosion loss of life personal injury and damage to this equipment and on site property do not operate or service this instrument before reading and understanding this instruction manual and receiving appropriate training Save these instructions DANGER ELECTRICAL SHOCK HAZARD Do not open while energized Installation requires access to live parts which can cause de...

Page 11: ...nformation WARNING HAZARDOUS AREA CERTIFICATION S Any addition substitution or replacement of components installed on or in this device must be certified to meet the hazardous area classification that the device was certified to prior to any such component addition substitution or replacement In addition the installation of such device or devices must meet the requirements specified and defined by...

Page 12: ...SURIZED GAS This unit requires periodic calibration with a known standard gas It also may utilizes a pressur ized carrier gas such as helium hydrogen or nitrogen See General Precautions for Handling and Storing High Pressure Gas Cylinders page P 5 CAUTION HEAVY WEIGHT Use two persons or a suitable lifting device to move or carry the instrument ...

Page 13: ... located in areas where extreme temperatures are prevalent 3 The valve protection cap should be left on each cylinder until it has been secured against a wall or bench or placed in a cylinder stand and is ready to be used 4 Avoid dragging rolling or sliding cylinders even for a short distance they should be moved by using a suitable hand truck 5 Never tamper with safety devices in valves or cylind...

Page 14: ...an Standards Association an OSHA Nationally Recog nized Testing Laboratory NRTL for USA and Canada European Union Conforms with the provisions of the EMC Directive 89 336 EEC Low Volt age Directive 73 23 EEC Potentially Explosive Atmospheres Directive 94 9 EC including amendments by the CE marking Directive 93 68 EEC EC type Examination Certificate LCIE 00 ATEX 6009 X Rosemount Analytical has sati...

Page 15: ...f develop ment and process expertise in sensors digital signal processing and software technologies The CAT 100 can satisfy the most demanding single or multi component analysis require ments More than 60 gas components can be measured including Carbon Monoxide CO Carbon Dioxide CO2 Methane CH4 Hexane CH equiv C6H14 Water Vapor H2O Oxygen O2 Hydrogen H2 Helium He Argon Ar Ethylene C2H4 Propane C3H...

Page 16: ...of two different measuring methods may be used as fol lows Interference Filter Correlation IFC With the IFC method the analysis cell is alternately illuminated with filtered infrared concentrated in one of two spectrally separated wavelength ranges One of these two wavelength bands is chosen to coincide with an absorption band of the sample gas and the other is chosen such that none of the gas con...

Page 17: ...on and Specifications 1 3 Model CAT 100 Figure 1 1 Absorption Bands of Sample Gas and Transmittance of Interference Filters Transmittance 0 18 36 54 72 90 Transmittance 0 15 30 54 60 75 90 CO2 CO Absorption Band HC CO2 CO Reference 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600 Wave Length nm ...

Page 18: ...ch is transparent for infrared ra diation The window is usually Calcium Fluoride CaF2 When the infrared radiation passes through the reference side of the analysis cell into the detector no pre absorption occurs Thus the gas inside the absorp tion chamber is heated expands and some of it passes through the flow chan nel into the compensation chamber When the infrared radiation passes through the o...

Page 19: ...ending on the application and need for reduction of influences Then the infrared radiation enters the analysis cells from which it is focused by filter cells onto the corresponding detector The preamplifier detector output signal is then converted into the analytical results expressed di rectly in the appropriate physical concen tration units such as percent volume ppm mg Nm3 etc This is shown in ...

Page 20: ...ecules enter the cell their paramagnetism will cause them to be drawn towards the region of greatest magnetic field strength The oxygen molecules thus exert different forces on the two suspended nitrogen filled quartz spheres producing a torque which causes the mirror to rotate away from its equilibrium position The rotated mirror deflects the incident light onto the photo detector creating an ele...

Page 21: ... Teflon membrane The electric current between the elec trodes is proportional to the O2 concentra tion in the sample gas being measured The resultant signal is measured as a voltage across the resistor and thermistor the latter of which is used for temperature compensation A change in the output voltage mV represents oxygen concen tration NOTE The electrochemical O2 cell requires a minimum interna...

Page 22: ... Rosemount Analytical Inc A Division of Emerson Process Management Model CAT100 Figure 1 6 Reaction of Galvanic Cell Red V out Black Thermistor 5 Resistor 6 Gold Lead Cathode 2 Anode 1 O2 4 H 4 e 2 H2O 2 Pb 2 H2O 2PbO 4 H 4 e Electrolyte 3 ph 6 Summary reaction O2 2 Pb 2 PbO ...

Page 23: ...hereat the reference gas path is closed for standard applications Always two sensors are located in the sam ple and the reference gas path The resistors are full glass packaged to withstand aggres sive gases The material in contact with the gases are glass Gold Aluminum stainless steel and Hastelloy so a high resistance against cor rosion by aggressive gases is provided by this cell Measurement Me...

Page 24: ...Instruction Manual 748441 D May 2004 1 10 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Model CAT 100 ...

Page 25: ...P 6 Corrosion Protection Option Instrument grade air is required Consult factory for requirements Ambient Range Temperature Standard 5 C to 45 C 41 to 113 F Temperature Optional 30 C to 50 C 34 to 122 F Relative Humidity 5 to 95 Inputs Outputs Digital RS 232 RS 485 serial data or FOUNDATION Fieldbus Analog Current Outputs Up to 2 isolated 4 20 mA common ground burden RB 500 ohms Analog Digital Out...

Page 26: ...uence of Pressure Standard 5 Pres Comp Opt 5 0 1 hPa 0 01 hPa 0 1 hPa 0 01 hPa 0 1 hPa 0 01 hPa 0 1 hPa 0 01 hPa Influence of Temperature On Zero On Span 2 On Span 2 6 1 5 7 1 1 1 1 1 2 1 1 5 7 2 Sensor Materials in Con tact with Sample Anodized Alum Stainless Steel gold coated BaF2 CaF2 Stainless Steel Platinum Glass PTFE PVDF FPM Epoxy resin Solvent resistant no FPM no epoxy but Nickel Kal rez A...

Page 27: ...ies and concentrations These calibration gases are normally introduced into the system as an input to the Sample Conditioning Plate Option or sample conditioning may be pro vided by others Each gas cylinder should be equipped with a clean hydrocarbon free two stage pressure regulator with indicating gauges of approxi mately 0 to 3000 psig 0 to 207 bar for cylin der pressure and 0 to 100 psig 0 to ...

Page 28: ...in Figure 2 3 page 2 4 may be required to pro vide pumping valving and throttling capabili ties as necessitated by the application Single or dual channel Ch in series 1 Gas Inlet Ch1 2 Gas Outlet Ch1 Dual channel in parallel 1 Gas Inlet Ch1 2 Gas Outlet Ch1 3 Gas Inlet Ch2 4 Gas Outlet Ch2 Single or dual channel in series including one auto calibration valve block 5 Outlet Span Zero Sample 6 Span ...

Page 29: ...rocess Management Installation 2 3 Model CAT100 Figure 2 2 Piping Diagram Two channel series Span gas 1 Span gas 2 Sample gas Zero gas V1 V2 V3 V4 Gas Sampling Pump option Channel 2 option Gas Outlet Flow Meter option Solenoid Valve Block option Channel 1 Throttle and Safety Filter option ...

Page 30: ...GEMENT SUBJECT TO APPLICATION C ELEVEN GAS CONNECTION PORTS IF REQUIRED FOR APPLICATION FLAME ARRESTOR S IN STALLED SEE FIGURE 2 1 B ANALOG AND DIGITAL I O PORTS M16 x 1 5 A INCREASED SAFETY JUNCTION BOX Note The Increased Safety Junction Box must be protected by fuse supply which has a breaking ca pacity adjusted to the short circuit of the equip ment DIMENSIONS INCH MM C 27 00 685 8 14 25 362 16...

Page 31: ...stituents Free of dust above 2 µm Free of aggressive constituents which may damage the gas paths Temperature and pressure in ac cordance with the specifications When analyzing vapors the dew point of the sample gas must be at least 10 C be low the ambient temperature in order to avoid the precipitation of condensate in the gas paths An optional barometric pressure compen sation feature can be supp...

Page 32: ...e Specification Section 1 4 page 1 11 c Gas Lines For external gas lines the use of all new tubing throughout is strongly recom mended The preferred type is new re frigeration grade copper tubing sealed at the ends Generally stainless steel tubing is less desirable as it contains hydrocar bon contaminants introduced through cleaning Pre cleaned and rinsed stain less steel tubing is available from ...

Page 33: ... are not nec essary for every application All analog digital inputs and ana log digital serial outputs are made through the Increased Safety Junction Box Cable length for these signals should not exceed 3 000 feet 914 me ters to avoid excessive capacitance and corresponding signal distortion The following connections are made through the Increased Safety Junction Box Electrical Power 2 Analog Outp...

Page 34: ...nal Assignments Terminal Description Bottom 10 C wht gry OK Failure open closed Bottom 11 C blk red OK Failure closed open Bottom 12 C blk org Measure Calibration open closed Bottom 13 C blk yel Measure Calibration closed open Bottom 14 C blk grn OK Failure common Bottom 15 C blk blu Measure Calibration common Bottom 20 D blk yel Pump Off On open closed Bottom 21 D blk blu Pump Off On closed open ...

Page 35: ...d Table 2 6 Power Connections Terminal Assignments Terminal Description 1 B Field Bus Line 2 B Field Bus Neutral 3 B Ground Table 2 7 Foundation Fieldbus Terminal Assignments option Connect AC power through a 10 A circuit breaker that is to be located close to the CAT 100 The circuit breaker will provide over current protection as well as a means of disconnecting the power Maximum power requiremen...

Page 36: ...odel CAT100 1 21 1 21 1 4 EMI Filter Bottom Power Top Figure 2 4 Increased Safety Junction Box Terminals NOTE If Foundation Fieldbus is selected then an other terminal strip will be located between the power connection and the connector for the analog digital serial inputs and outputs consult factory for further information ...

Page 37: ...ng the integrity of the sample containment system a Flow Indicator Method Supply air or inert gas such as nitrogen at 10 psig 689 mbar to the analyzer through a flow indicator with a range of 0 to 250 cc min Install a shut off valve at the sample gas outlet Set the flow rate to 125 cc min ml min Close the outlet shut off valve and notice that the flow reading drops to zero If the flow reading does...

Page 38: ...riod for pressure equilibrium verify that the height of the water column does not drop over a period of about 5 minutes If the water column height drops the system is leaking and must be cor rected before the introduction of any flammable sample gas or application of power Figure 2 6 Leak Check Manometer Method NOTE Refer to Section 1 4 Specifications page 1 11 for maximum pressure limitations For...

Page 39: ...splay represents any character NOTE In the case of a battery failure in the ana lyzer the programmed values will revert to defaults and the display will flash batt on power up This message will disappear after activating any pad The battery maintains the memory for pro grammed parameters when the analyzer is shut off 3 2 TOUCHPAD a Overview CAT 100 analyzers intended either to be used in hazardous...

Page 40: ...mounting bolts as shown in Figure 3 3 page 3 2 The mounting provides a hook to store the actuator tool when not in use Figure 3 3 Storing The Actuator Tool d Operation The Touch pad is operated by reflecting the infrared light coming out of the drill hole into the corresponding entry hole This is done by holding the actuator tool s bent end Figure 3 2 page 3 2 in front of the key in a way that is ...

Page 41: ...ion directly above the touch pad on the outside of the glass window It is not necessary to make contact with the glass window Various prompts will appear on the two 4 digit LED displays The stored parameters are maintained during power off by the means of a battery powered memory In the case of a battery failure in the analyzer the programmed values will revert to de faults and the display will fl...

Page 42: ... Control entry The ana lyzer will continue to perform analysis throughout touch pad entry procedures The following are the analyzer Func tions and their sequences Zeroing channel 1 Zeroing channel 2 Spanning channel 1 Spanning channel 2 Interval Time for automatic Zeroing1 Interval Time for automatic Spanning 1 Entry of concentration limits Entry of system parameters Entry of serial interface para...

Page 43: ...odes as shown in Figure 4 2 and as described in the following sections The password has been set to the value 1 at the factory We would recommend to change the password immediately after start up for safety reasons Please use a password with two digits See also item j for more information h INPUT CONTROL Touch pads The Input Control pads are used for the adjustment of the individual entry pa ramet...

Page 44: ...Instruction Manual 748441 D April 2002 3 6 Operation Rosemount Analytical Inc A Division of Emerson Process Management Model CAT100 Optional Figure 3 7 Analyzer Operating Function Matrix ...

Page 45: ...le gas pressure re spectively Use the INPUT CONTROL pads to change the value and then activate ENTER NOTE An optional pressure sensor with a range of 800 1100 hPa can be in corporated so that the concentration values will be automatically cor rected for barometric pressure In this case it is not possible to enter the pressure value manually Any at tempt to enter the pressure value manually will be...

Page 46: ...red values during a calibration procedure Entry of 0 The outputs remain unlocked Entry of 1 The outputs will be locked during a calibration Use the INPUT CONTROL pads to change the value and then activate ENTER e Automatic Calibration This function enables or disables auto matic calibration when the analyzer is equipped with the optional internal or external solenoid valves Digital outputs are als...

Page 47: ...tput signal of 2 10 V op tion 0 2 1 V 4 20 mA Use the INPUT CONTROL pads to change the value and then activate ENTER NOTE The zero and range values may be programmed See Sections 3 3l page 3 10 and 3 3m page 3 10 For the type of voltage output refer to the order confirmation or the iden tification plate See Section 2 2g page 2 7 for termi nal assignments of the analog outputs in the Increased Safe...

Page 48: ... gas concentration of 10 The dis played values are not affected Use the INPUT CONTROL pads to change the value and then activate ENTER If the analyzer is equipped with a sec ond channel the offset for the second channel is also presented for adjust ment NOTE The analyzer is supplied from the factory with the offset set to 0 It is up to the user to change the value if desired m Range Value This fun...

Page 49: ...enever a reset operation is per formed the analyzer operating program will be restarted just as it is when the analyzer is first switched on NOTE Jumper J6 on circuit board BKS which activates the watchdog cir cuitry must be inserted if the reset operation is to be correctly exe cuted See Section 5 5a page 5 29 o Program Version This function displays the installed software version number This num...

Page 50: ...ted by digital outputs for the respective function If the ana lyzer is in calibration mode an op tional digital status signal calibration output is activated a Zeroing For zeroing the analyzer has to be flushed with nitrogen N2 or an ade quate zero gas such as synthetic or conditioned air Air cannot be used for oxygen zeroing b Spanning The span gas concentration should be in the range or 80 to 11...

Page 51: ...UNCTION pad If the actual and nominal values dis agree activate the ENTER pad and the display will show Or The actual measuring value To start the zeroing process activate ENTER again As soon as the zeroing has finished the display shows Or The actual measuring value The touch pad will only be released af ter another flushing period and t90 time The analog output signals and the concentration limi...

Page 52: ...OL pads and then activate ENTER The display will now show Or The actual measuring value If the actual and nominal values agree span calibration is not necessary and the next function can be selected using the FUNCTION pad If the actual and nominal values dis agree activate the ENTER pad to start the spanning As soon as spanning has finished the display will show Or The actual measuring value The t...

Page 53: ...NTER pad If the user password code has not yet been entered the password entry dis play will show Using the INPUT CONTROL pad enter the correct password code and activate ENTER The display will now show Use the INPUT CONTROL pads enter a time interval in hours when automatic zeroing is to be performed The range of accepted entries in 0 399 hours Activate the ENTER pad to accept the entry Automatic...

Page 54: ...ate the ENTER pad If the user password code has not yet been entered the password entry display will show Using the INPUT CONTROL pad enter the correct password code and acti vate ENTER The display will now show Use the INPUT CONTROL pads to set the lower limit for channel 1 Then activate the ENTER pad and the following will appear Use the INPUT CONTROL pads to set the upper limit for channel 1 Th...

Page 55: ... a period of 60 120 seconds has elapsed after the last pad activation or completion of an operation Al ternately the user can activate the FUNC TION pad until the analysis mode displays Analyzers With Electrochemical O2 De tector The electrochemical O2 cell requires a minimum internal consumption of oxygen Sample gases with an oxygen concentra tion of less than 2 could result in a re versible detu...

Page 56: ...ditioned air For analyzers with electro chemical O2 detector purge all analyzer gas lines with conditioned ambient air be fore closing any gas line fittings for trans port or storage of the analyzer The full procedure for shutting down is as follows Admit zeroing gas to the respective gas inlet fitting Switch on the optional gas pump Set the flow rate to an allowable rate After 5 minutes Switch of...

Page 57: ... in longer life for the heaters and temperature controller NOTE If the temperature is changed from the factory setting of 50 C then the ana lyzer must be re calibrated at the newly set temperature See Sections 3 4 page 3 12 3 5 page 3 13 or 3 6 page 3 15 for calibration procedures NOTE When equipped with this temperature stabilization option allow the analyzer to reach operating temperature before...

Page 58: ... CAT 100 DIP switch settings The DIP switch is accessible through an opening on the side of the case Af ter carefully removing the controller from the case locate the DIP switch and set the switches according to the following Initial menu settings Upon applying power the controller will first flash reset on the PV display and the software version number on the SV display and then begin the Run Mod...

Page 59: ...isable MENUX Out 1 ENTER MAX o0L0 0000 Percent Low 0 MIN MAX ENTER o0HI 0099 Percent High 99 MIN MAX ENTER CtrL On OF Control Type On Off ENTER MAX ENTER Actn rur5 Action Type Reverse Acting ENTER MAX ENTER dEAd 001 0 Dead Band 1 0 ENTER MAX MIN ENTER rANP dSbL Ramp and Soak disabled MENU X rANP SoAC ENTER ENTER MAX ENTER Final menu settings Make sure the controller is in Run Mode Allow the heater...

Page 60: ...Instruction Manual 748441 D April 2002 3 22 Operation Rosemount Analytical Inc A Division of Emerson Process Management Model CAT100 ...

Page 61: ...ate character Upon receipt of the terminate character the analyzer attempts to evaluate the current con tents of its input buffer as a valid string If the syntax of the transmitted string is correct the analyzer will transmit a response string to the host computer This consists of the start char acter an instruction code requested data a block parity byte and the termination charac ter If the synt...

Page 62: ...elected from LB1 on PCB SIP485 Connect pins 1 2 for 2 wire op eration or pins 2 3 for 4 wire operation For network operation with several ana lyzers jumper P2 must be installed at each end of the network Analyzers in between must have P2 removed In contrast to RS232C operation simulta neous transmission and reception is not implemented Although there would be no damage to the electronics simultane...

Page 63: ... communications The following analyzer parameters can be set Baud rate 600 1200 2400 4800 Data bits 8 Stop bits 2 Parity bit none Echo mode on off received charac ters will be retransmitted immediately LPB test on off message length parity check ID number 0 to 99 device ID number in RS485 mode All entries are made us the INPUT CONTROL pads and the ENTER pad Activate the FUNCTION pad until appears ...

Page 64: ...ode If a received instruction code should be other than three digits in length or contain non numerical ASCII charac ters the analyzer will transmit an appropriate status string Reception of unassigned instruc tion codes will also result in the transmittal of a status string In the RS232C mode of operation the instruc tion code immediately follows the start charac ter In the RS485 mode of operatio...

Page 65: ...D xxx S104 LPB CR Analyzer off line status ID xxx S105 LPB CR Text line too long ID xxx S106 LPB CR Undefined instruction ID xxx S107 LPB CR Invalid integer value ID xxx S108 LPB CR Numerical value outside defined range ID xxx S109 LPB CR Invalid failure status code ID xxx S110 LPB CR Instruction cannot be done here ID xxx S111 LPB CR Failure in transmitted character ID xxx S112 LPB CR Zeroing run...

Page 66: ...gits accepted No alphabetic characters allowed Analyzer output are 6 digit real numbers c Block Parity Check The host computer may insert a mes sage length parity byte into the strings These must be two characters The message length parity byte is the cumulative exclusive or correlation of all previously transmitted characters of the string line Representation is in hexa decimal format For example...

Page 67: ... m k LPB CR RI span gas valve open ID 006 LPB CR RI on line status ID 007 LPB CR RI off line status ID 011 m k LPB CR SP at full scale range ID 013 k LPB CR SP t90 response time ID 014 w k LPB CR RP t90 response time ID 017 k LPB CR SP pre flushing period ID 018 w k LPB GR RP pre flushing period ID 019 k LPB CR SP Pre Flushing period ID 020 w k LPB CR RP Pre Flushing period ID 023 k LPB CR SP conc...

Page 68: ...or instruction ID 030 LPB CR SP Status messages Is as follows ID 030 a b c LPB CR Where Value Meaning a OK Status 0 Relay without power 1 Relay active b Calibration 0 No calibration 1 Zeroing channel 1 2 Zeroing channel 2 3 Zeroing channel 1 2 4 Spanning channel 1 5 Spanning channel 2 6 Spanning channel 1 2 7 Spanning channel 1 first then channel 2 8 Reserved 9 Reserved 10 Waiting for flushing tim...

Page 69: ... Troubleshooting Guide in Section 6 for tips on isolating typical faults Also refer to Section 2 Installation and Section 3 Op eration to verify that the analyzer is being operated properly Likewise some faults can be traced to ancillary equipment Check all equipment which is connected to the CAT 100 espe cially all gas paths both sample and cali bration b Analyzer Replacement The CAT 100 is uniqu...

Page 70: ...re opening the explosion proof housing Failure to purge the housing before open ing could result in an explosion WARNING ELECTRICAL SHOCK HAZARD Disconnect power from the CAT 100 before opening and removing any components Failure to remove power can result in elec trical shock The CAT 100 explosion proof enclosure is comprised of three major sections the base the extender housing and the dome hous...

Page 71: ...gas line fittings with PVC caps after removal of the analyzer b Analyzer Replacement 1 Slide the analyzer onto the mounts being careful that the screws and washers are on the outside 2 Locate the analyzer in the exact same location as when removed by aligning the screws with the alignment marks previously made 3 Tighten the screws 4 Make sure the dome threads are clean and free of any contaminants...

Page 72: ...aramagnetic or elec trochemical and one Infrared Photome ter In addition the following major compo nents may be present Gas sampling pump with a maximum pumping rate of 2 5 l min not included on two channel analyzer with parallel gas paths An indicator light is provided on the front panel to show when the pump is on Option pressure sensor range of 800 to 1100 hPa With the pressure sensor in stalle...

Page 73: ...ent Layout Infrared Channel Oxygen Measurement Combined Circuit board BKS under photome Solenoid Valves FOUNDATION Fieldbus option IR Photometer depending on ana Paramagnetic Oxygen Sensor depending on ana Gas Sampling Pump Pressure Sen sor Electrochemical Oxygen Sensor with circuit board OXS depending on analyzer Front Panel Digital Inputs option Channel 1 alt Channel 2 ...

Page 74: ...Emerson Process Management Model CAT100 Figure 5 3 Analyzer Component Layout 1 Channel Oxygen Measurement Electrochemical Gas Sampling Pump Electrochemical Oxygen Sensor with circuit board OXS Circuit board BKS Solenoid Valves Front Panel Pressure Sen sor Channel 1 Digital Inputs option FOUNDA TION Fieldbus ...

Page 75: ...5 4 Analyzer Component Layout Paramagnetic Oxygen Measurement Thermal Conductivity Combined Gas Sampling Pump Thermal Conductiv ity Detector depending on ana Circuit board BKS Solenoid Valves Front Panel Pressure Sen sor Digital Inputs option FOUNDA TION Fieldbus Paramagnetic Oxy gen Detector depending on ana Thermal Conductiv ity Thermal Conductiv ity ...

Page 76: ...out Infrared Channel Thermal Conductivity Combined Gas Sampling Pump Thermal Conductiv ity Detector depending on ana Circuit board BKS Solenoid Valves Front Panel Pressure Sen sor Channel 1 Digital Inputs option FOUNDA TION Fieldbus Thermal Conductiv ity Thermal Conductiv ity IR Photometer depending on ana Electrochemical Oxygen Sensor with circuit board OXS Channel 2 Channel 2 ...

Page 77: ... chopper blade driven by a stepping motor Both the chopper housing and the motor encapsu lation are hermetically sealed with respect to ambient in order to prevent entry of gases such as atmospheric CO2 which could produce background absorptivity pre absorption leading to drift effects An absorber material provides for constant removal of any traces of C02 which may enter the interior of the chopp...

Page 78: ...uplex Filter Disc 06 Zero Adjustment Baffle not in sealed photometer 07 Light Source thermal radiator 08 Analysis Cell 1 7 mm spacer ring 09 Analysis Cell 50 200 mm 10 Adapter Cell 14 15 Filter Cell 16 Detector 17 Flange light source 18 21 O Rings 22 Clamp analysis cells 1 7 mm 23 Clamping Collar analysis cells 1 7 mm 25 Clamp analysis cells 50 200 mm 26 Light Source Mounting Screws 27 Mounting Sc...

Page 79: ...h ends are sealed with windows This divides the analysis cell into measuring side and reference side Sample gas flows through the measuring side while the closed reference side con tains inert gas N2 To prevent measuring errors by pre absorption Two absorbers fitted to the gas connectors of the reference side ab sorb CO2 components The filter cell has a single stage conical shape The gas detector ...

Page 80: ...id valve calibration gas inlet 2 option 8 Solenoid valve common gas outlet fitting option 9 Digital inputs option 10 Socket analog signal outputs X2 11 Socket serial interface RS232C 485 option 12 Plug output relays option 13 Plug digital limit outputs 14 Solenoid valve sample gas inlet option 15 Solenoid valve zero gas inlet option 16 24 VDC input 17 Foundation Fieldbus option Figure 5 8 Analyzer...

Page 81: ...Relays 9 Pos D Subminiature Plug X4 OUTPUT 9 Pos D Subminiature Socket Optional RS232C Interface optically isolated 6 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 5 Optional RS485 Interface optically isolated Gnd RxD TxD Not used Gnd Not used Not used Not used Not used Gnd RxD RxD TxD TxD Not used Not used Not used Not used 1 5 6 9 1 2 3 4 5 6 7 8 9 Limit channel 2 max Limit channel 2 min Limit channel...

Page 82: ...sages for the sample gas As supplied these passages are set aligned with the gas fittings see Figure 5 10 page 5 15 This means that the in strument is supplied as standard set for a short response time and a relatively large dependence on sample gas flow rate To alter the response time loosen the Al len head screws on the sensor and rotate the outer annular chamber section The greatest response ti...

Page 83: ...D April 2002 Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Service 5 15 Model CAT100 Figure 5 10 TC Sensor Short Response Time Setting Standard Figure 5 11 TC Sensor Long Response Time Setting ...

Page 84: ...her maintenance operations may be required more or less frequently depending upon experience usage and site conditions b Checking and Cleaning of the Analyzer If the analyzer is removed from the explo sion proof enclosure for any reason it should be cleaned and the electronics checked for any obvious faults 1 Remove the analyzer from the enclo sure see Section 5 2a page 5 3 2 Clean the outside of ...

Page 85: ...ssembly and the electronic unit and remove all gas lines from the photometer as sembly 4 On analyzers with gas detector re move preamplifier Figure 5 7 page 5 11 from holding device 5 Remove the two screws shown in Figure 5 12 page 5 17 as item 1 6 Remove the photometer assembly from the analyzer housing as a unit 1 Fastening screw photometer assembly mounting bracket 2 Light source with mounting ...

Page 86: ...ource together with its mounting flange 6 Remove the mounting flange from the light source and position it on the new light source 7 For sealed version with pyroelectrical detector only remove the zero level adjustment baffle from the light source and position it in the new light source 8 For sealed version only place the O rings on the adapter cell and filter cell 9 Insert the new light source an...

Page 87: ...igure 5 13 page 5 19 as item 2 2 Remove the clamping collar and the filter cell with signal detector assem bly For analysis cells of 50 mm to 100 mm length 1 Remove the clamp shown in Figure 5 13 page 5 19 as item 3 2 Remove the filter cell with signal de tector assembly 3 Remove the mounting screws shown in Figure 5 13 page 5 19 item 4 4 Remove the analysis cell body from the chopper housing 5 On...

Page 88: ...ollars with the clamp and tighten For analysis cells of 50 mm 200 mm length 1 Place the O ring on the chopper housing side of the cell body 2 Position the cell body in place and fasten using the two mounting screws as shown in Figure 5 13 page 5 19 item 4 3 Place the O rings on the filter cell 4 Fit the filter cell on the cell body 5 Install the clamp and tighten 6 For an analyzer with a gas detec...

Page 89: ...e light source mounting screws Figure 5 13 page 5 19 item 5 or the temperature sen sor Figure 5 13 item 3 respectively for channel 1 or channel 2 2 Set the zero level to precisely 0 V 100 mV by turning the correspond ing light source 3 For photometer with pyroelectrical detector only a To facilitate the physical zero level adjustment there is built into the light source one of three different tigh...

Page 90: ...ommended practice is to purge the cell with conditioned am bient air between periods of measure ment If the oxygen concentration is below 0 1 for several hours or days the cell must be regenerated for about one day with ambient air Temporary flushing with nitrogen N2 for less than one hour analyzer zeroing will have no effect on the sensitivity or stability k Check of the Sensor Exchange the senso...

Page 91: ...S connectors X5 X6 and X7 refer to Section 5 5a page 5 29 4 Remove all gas lines from the sen sors 5 Unscrew both allen screws shown in Figure 5 15 page 5 23 6 Remove the support bracket from the top of the analyzer 7 Disconnect the connector P2 from the OXS PCB see Figure 5 16 page 5 24 8 Cut and remove the tie wrap as shown in Figure 5 17 page 5 24 9 Unscrew both fastening screws for the fitting...

Page 92: ...erson Process Management Model CAT100 Figure 5 16 OXS PCB Connector P2 Figure 5 17 Oxygen Sensor Support Oxygen Measurement Without Infrared Channel Sensor OXS PCB Connector for Sensor Potentiometer R4 Gas connections Sensor nameplate Tie Wrap Fastening screw Fitting Fastening screw Oxygen Sensor Connector P2 ...

Page 93: ...he analyzer from the enclo sure see Section 5 2a page 5 3 2 Remove the analyzer cover see Sec tion 5 4b page 5 16 3 Disconnect the connector P2 from the OXS PCB see Figure 5 16 page 5 24 4 Unscrew both fastening screws for the fitting see Figure 5 18 page 5 25 and remove the fitting complete with the sensor Figure 5 18 Oxygen Sensor with Infrared Channel Front Panel Gas connections Fastening screw...

Page 94: ...m the sensor to P2 of OXS PCB see Figure 5 16 page 5 24 4 Insert the complete support Figure 5 18 page 5 25 into the analyzer and attach with the two allen screws see Figure 5 15 page 5 23 5 Reconnect all gas lines to the fittings see Figure 5 15 page 5 23 and Figure 5 17 page 5 24 Be careful not to interchange gas inlets and gas outlets 6 Reconnect all electrical connections between OXS and BKS c...

Page 95: ...the cover Return the analyzer to the ex plosion proof housing 6 Perform a complete zero and span calibration after a sensor replace ment Figure 5 19 OXS PCB Location of Measuring Points and Voltage Adjustment n Sample Pump Maintenance The optional built in sample pump re quires regular replacement of the dia phragm The replacement interval is determined by the constituents in the sample gas which ...

Page 96: ... it c If the Pressure Sensor option BAF 01 is installed the EPROM is located on the BAF circuit board d Correctly orient the new EPROM with respect to the socket before re insertion The EPROM is in serted correctly if the half moon mark is facing the front panel of the analyzer as shown in Figure 5 20 page 5 28 e Reconnect the jumper J7 5 Reconnect that analyzer to the power source and switch it o...

Page 97: ... 10 200 mV Adjust with potentiometer R90 if necessary Failure No signal Possible reasons Voltage supply absent Voltage supply 9 V or polarity reversed BKS PCB faulty Reference Voltage Positive Test Point X 10 Test Device DVM Signal 5 535 V DC 60 mV Reference Voltage Negative Test Point X 12 Test Device DVM Signal Inverse of reference Voltage positive The difference between the negative and positiv...

Page 98: ...nt µP not working Check if EPROM is in serted correctly perform a reset or replace BKS PCB Temperature Sensor Test Point X 8 Test Device DVM Signal 0 500 mV DC at am bient temperature Failure Signal 3 5 V DC Possible reasons IR measurement or paramagnetic oxygen measurement Temperature sensor not connected Temperature sensor faulty replace sensor Broken cable on sensor replace sensor BKS PCB fault...

Page 99: ...analyzer off and then on again Broken cable to light bar rier or faulty light barrier replace chopper BKS PCB faulty replace BKS Possible reasons oxygen measurement without infrared channel Solder bridge LB 18 not closed BKS PCB faulty replace BKS Analog Preamplifier paramagnetic oxygen measurement Test Point X 25 channel 1 Test Device DVM Signal At zero gas purge 0 V DC 50 mV At ambient air 21 O2...

Page 100: ...nalyzer without oxygen meas urement X27 channel 2 Test Device DVM Signal At zero gas purge 0 V DC 100 mV There should be a mini mum difference of 600 mV measuring range 1000 ppm difference 500 mV between zero point voltage and sensitivity voltage Failure No signal or incorrect measuring values Possible rea sons Detector sensor not con nected Detector sensor faulty replace detector BKS PCB faulty r...

Page 101: ...Pressure sensor PCB P1 Option BAF 01 Connector for pres sure sensor IR measurement without oxygen chan nel X2 Chopper X3 4 5 Light source channel 1 X3 1 2 Light source channel 2 X5 IR detector channel 1 X6 IR detector channel 2 X7 Temperature sensor chopper X9 Light barrier chopper Oxygen measurement without infrared channel X5 Oxygen sensor electrochemical measurement OXS PCB cable P1 5 pin conne...

Page 102: ...Inc A Division of Emerson Process Management Model CAT100 Jumper Locations on BKS PCB J1 A D conversion Start channel 1 J2 A D conversion Start channel 2 open for 1 channel analyzer J6 Watchdog signal J7 Buffer battery Figure 5 23 BKS PCB Jumper Locations X16 X18 J6 J7 J2 J1 1 1 Front Panel ...

Page 103: ...P2 gnd Test Device DVM Signal At ambient air 21 O2 700 mV to 1000 mV Failure No signal or incorrect voltage Possible rea sons Oxygen sensor not con nected to OXS PCB OXS PCB not connected or faulty Oxygen sensor faulty or consumed BKS PCB faulty replace BKS NOTE If the signal value is lower that 700 mV at gas flow with ambient air the sensor is consumed Replace the sensor 4 Figure 5 24 OXS PCB Tes...

Page 104: ...ivision of Emerson Process Management Model CAT100 Plug Locations on OXS PCB Pin base P2 Oxygen sensor Cable P1 5 pin connectorBKS PCB X5 sensor signal Cable P1 2 pin connectorBKS PCB X7 tempera ture sensor not used in combina tion with infrared measurement Figure 5 25 OXS PCB Plug Locations P2 P1 ...

Page 105: ...s located in the base of the explosion proof enclosure beneath the analyzer Removal of the analyzer Section 5 2a page 5 3 is nec essary to service the power supply Test Point TP1 TP2 gnd Test Device DVM Signal 24 V DC 1 V Failure No voltage or incor rect voltage Possible rea sons Faulty power supply replace Figure 5 26 Power Supply Connections Neutral Hot AC POWER EMI Board Fuses TP1 TP2 ...

Page 106: ...Instruction Manual 748441 D April 2002 5 38 Maintenance and Service Rosemount Analytical Inc A Division of Emerson Process Management Model CAT100 ...

Page 107: ...n 3 3g page 3 9 2 No power to analyzer Check electrical supply No Display 3 Front panel BKS connection absent Check connection on BKS PCB X1 1 Battery buffer faulty Check if jumper J7 is plugged in Flashing 2 The EPROM default values were changed Exchange battery if battery voltage is 3 5 V The error is cleared by activating any pad or with serial interface instruction 627 1 Jumper not plugged in ...

Page 108: ...he tolerance check before starting an adjustment See Section 3 3f page 3 8 1 Incorrect nominal value Enter the correct nominal value See Section 3 5b page 3 13 2 Incorrect span gas in use Check span gas in use Use another or new gas bottle Enter the correct nominal value 3 IR channel photometer section contaminated Check analysis cell and windows for contamination See Section 5 4f page 5 20 Channe...

Page 109: ... and 6 2 page 5 6 2 Ambient air contains gas constituent to be measured in excessive concentration Replace absorber material for the light sources and chopper housing Use sealed photometer option Flush out the analyzer 3 Gas pressure subject to excessive fluctuations Check the gas line preceding and following the sensor cell Eliminate any restrictions found beyond the gas outlet fitting Reduce pum...

Page 110: ...ochemical oxygen sensor is already consumed Replace sensor See Section 5 4j page 5 21 12 IR Channel light source not connected or faulty Check connection BKS PCB X3 1 2 light source channel 1 BKS PCB X3 4 5 light source channel 2 Light source is cold For dual infrared channel analyzer exchange the two light sources Replace the suspected light source See Section 5 4d page 5 18 13 Faulty analog prea...

Page 111: ...der adding a bypass line to the process stream for sampling purposes Response time too long t90 time 3 Contamination of the gas paths Check gas paths and gas conditioning for contamination Clean gas paths and change the filter elements 1 Optional needle valve not open Open needle valve 2 Sample gas pump not on Check connections 3 Pump membrane defective Change membrane on pump 4 Sample gas pump de...

Page 112: ...er all fittings seals and other pos sible sources of leakage with a suitable leak check liquid such as SNOOP PN 837801 Bubbling or foaming indicates leakage Check ing for bubbles will locate most leaks but could miss some as some areas are inaccessible to the application of SNOOP For positive assur ance that system is leak free perform one of the tests in Section 2 3 page 2 11 ...

Page 113: ... to instructions provided in the Rosemount Return Authorization prepaid to Emerson Process Management Process Analytic Division Customer Service Center USA 1 800 433 6076 EMERSON Process Management Manufacturing GmbH Co OHG D 63594 Hasselroth Germany Industriestr 1 EU 49 6055 884 0 Fax 209 If warranty service is expected the defective unit will be carefully inspected and tested at the factory If t...

Page 114: ...Instruction Manual 748441 D April 2002 7 2 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Model CAT100 ...

Page 115: ...ge the internal temperature setting 3 19 concentration limits lock 3 8 unlock 3 8 D dewpoint of the sample gas 2 5 dwell time for calibration gas flow 3 9 E electrical response time 3 10 electrochemical method of determining oxygen concentration 1 7 electrochemical O2 cell 3 17 electrochemical oxygen sensor 1 7 5 21 life time 5 21 external flow meter 2 1 external gas lines 2 6 F factory settings r...

Page 116: ... 5 9 pyroelectrical detector 1 2 5 11 5 18 5 21 R Return Authorization 7 1 reversible detuning of sensitivity 3 17 S Sample Conditioning Plate Option 2 1 Sample Handling Plate 2 2 2 5 sample pump 5 27 Sample pump 2 2 software version displaying 3 11 solenoid valves 3 4 3 8 3 12 3 15 4 7 5 4 5 span gas setpoint 3 13 start the zeroing process 3 13 syntax 4 1 4 5 4 8 hyphen character 4 4 instruction ...

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Page 119: ...ATE OPTION SIZE AND ARRANGEMENTSUBJECT TO APPLICATION 6 1 SHOWSTYPICAL 4 101 6mm PIPE MOUNT CLAMPSTO BE SUPPLIED BY I MOUNTING FOR ANAL YZER ROSEMOUNT PIPE MOUNT MAY BE SUPPLIED BY ROSEMOUNT IF ORDERED 1 WITHOUT STAND ALL VENT LINES TO INCLINE MINIMUM OF 6 DEGREES L______ FLAME ARRESTORS INSTALLED IF REOUIRED FOR APPLICATION OTHERWISE A PLUS IS INSTALLED ALL TUBING CONNECTIONS ARE 1 4 6 4 TUBE EXC...

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Page 121: ...ctly or indirectly arising from the use of the equipment or goods from breach of any warranty or from any other cause All other warranties expressed or implied are hereby excluded IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY NO OTHER WAR RANTIES ARE GRANTED INCLUDING BUT NOT LIMITED TO EXPRESS AND IMPLIED WARRANTIES OR MERCH...

Page 122: ... Pandan Crescent Singapore 128461 Republic of Singapore Phone 65 777 8211 Fax 65 777 0947 http www processanalytic com Fisher Rosemount GmbH Co Industriestrasse 1 63594 Hasselroth Germany Phone 49 6055 884 0 Fax 49 6055 884209 EUROPE MIDDLE EAST AND AFRICA Fisher Rosemount Ltd Heath Place Bognor Regis West Sussex PO22 9SH England Phone 44 1243 863121 Fax 44 1243 845354 LATIN AMERICA Fisher Rosemou...

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