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System Reference Manual
2-3-9000-744, Rev G
September 2014
700XA Gas Chromatograph
Applies to the Rosemount® Analytical 700XA Gas Chromatograph
and the Danalyzer™ 700XA Gas Chromatograph
Page 2
NOTICE
ROSEMOUNT ANALYTICAL, INC. (“SELLER”) SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS IN THIS MANUAL OR
OMISSIONS FROM THIS MANUAL. SELLER MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND, IN NO EVENT, SHALL
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PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER IDENTIFICATION ONLY AND MAY BE TRADEMARKS/
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IMPLIED, REGARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICABILITY. WE RESERVE THE RIGHT
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PROPER SELECTION, USE AND MAINTENANCE OF ANY SELLER PRODUCT REMAINS SOLELY WITH THE PURCHASER AND END-USER.
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EMERSON LOGO IS A TRADEMARK AND SERVICE MARK OF EMERSON ELECTRIC CO.
©
2014
ROSEMOUNT ANALYTICAL INC.
HOUSTON, TX
USA
All rights reserved. No part of this work may be reproduced or copied in any form or by any means—graphic, electronic, or
mechanical—without first receiving the written permission of Rosemount Analytical Inc., Houston, Texas, U.S.A.
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Warranty
1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise expressly provided
herein, Rosemount Analytical, Inc. (“Seller”) warrants that the firmware will execute the programming instructions provided
by Seller, and that the Goods manufactured or Services provided by Seller will be free from defects in materials or
workmanship under normal use and care until the expiration of the applicable warranty period. Goods are warranted for
twelve (12) months from the date of initial installation or eighteen (18) months from the date of shipment by Seller,
whichever period expires first. Consumables and Services are warranted for a period of 90 days from the date of shipment or
completion of the Services. Products purchased by Seller from a third party for resale to Buyer (“Resale Products”) shall carry
only the warranty extended by the original manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond
making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If Buyer discovers
any warranty defects and notifies Seller thereof in writing during the applicable warranty period, Seller shall, at its option,
promptly correct any errors that are found by Seller in the firmware or Services, or repair or replace F.O.B. point of
manufacture that portion of the Goods or firmware found by Seller to be defective, or refund the purchase price of the
defective portion of the Goods/Services. All replacements or repairs necessitated by inadequate maintenance, normal wear
and usage, unsuitable power sources, unsuitable environmental conditions, accident, misuse, improper installation,
modification, repair, storage or handling, or any other cause not the fault of Seller are not covered 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 shall be borne by Buyer unless accepted in writing by Seller. Goods repaired and parts replaced during the warranty
period shall be in warranty for the remainder of the original warranty period or ninety (90) days, whichever is longer. This
limited warranty is the only warranty made by Seller and can be amended only in a writing signed by an authorized
representative of Seller. Except as otherwise expressly provided in the Agreement, THERE ARE NO REPRESENTATIONS OR
WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, OR
ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. It is understood that corrosion or erosion of
materials is not covered by our guarantee.
2. LIMITATION OF REMEDY AND LIABILITY: SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE.
THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY HEREUNDER SHALL BE LIMITED TO REPAIR, CORRECTION,
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GIVING RISE TO THE CLAIM OR CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY TO BUYER
AND/OR ITS CUSTOMERS EXTEND TO INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. THE TERM
“CONSEQUENTIAL DAMAGES” SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE,
LOSS OF REVENUE AND COST OF CAPITAL.
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Contents
Contents
Chapter 1 Introduction ...................................................................................................................1
1.1 Description of manual ..................................................................................................................1
1.2 System description ...................................................................................................................... 1
1.2.1 Analyzer assembly .........................................................................................................1
1.2.2 Electronics assembly ..................................................................................................... 1
1.2.3 Sample conditioning system (SCS) ................................................................................ 2
1.3 Functional description ................................................................................................................. 2
1.4 Software description ....................................................................................................................3
1.4.1 Embedded GC firmware ................................................................................................ 3
1.4.2 MON2020 ..................................................................................................................... 4
1.5 Theory of operation ..................................................................................................................... 5
1.5.1 Thermal conductivity detector ......................................................................................5
1.5.2 Flame ionization detector ..............................................................................................7
1.5.3 Liquid sample injection valve .........................................................................................7
1.5.4 Methanator ...................................................................................................................8
1.5.5 Data acquisition ............................................................................................................ 9
1.5.6 Peak detection .............................................................................................................. 9
1.6 Basic analysis computations .......................................................................................................10
1.6.1 Concentration analysis - response factor ..................................................................... 10
1.6.2 Concentration calculation - mole percentage (without normalization) ........................11
1.6.3 Concentration calculation in mole percentage (with normalization) ........................... 12
1.7 Glossary .....................................................................................................................................12
Chapter 2 Equipment description and specifications .................................................................... 15
2.1 Equipment description .............................................................................................................. 15
2.1.1 Front panel assembly .................................................................................................. 15
2.1.2 Upper compartment ................................................................................................... 19
2.1.3 Lower compartment ................................................................................................... 19
2.1.4 Mechanical pressure regulators ...................................................................................20
2.2 Equipment specifications ...........................................................................................................21
2.2.1 Utilities ........................................................................................................................21
2.2.2 Electronic hardware .................................................................................................... 22
2.2.3 Airless analytical oven ................................................................................................. 23
2.2.4 Software ..................................................................................................................... 23
2.2.5 Corrosion protection ...................................................................................................24
2.2.6 Archived Data Storage Capabilities ..............................................................................24
Chapter 3 Installation and setup ...................................................................................................27
3.1 Precautions and warnings .......................................................................................................... 27
3.1.1 Installation considerations .......................................................................................... 29
3.2 XA mounting arrangements ...................................................................................................... 29
3.2.1 Wall mount ................................................................................................................. 30
3.2.2 Pole mount ................................................................................................................. 31
3.2.3 Floor mount ................................................................................................................ 32
3.3 Gas chromatograph wiring ........................................................................................................ 33
3.3.1 Power source wiring ....................................................................................................33
3.3.2 Signal wiring ............................................................................................................... 33
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3.3.3 Electrical and signal ground .........................................................................................34
3.3.4 Electrical conduit .........................................................................................................35
3.3.5 Sample system requirements ......................................................................................36
3.4 Preparation ................................................................................................................................37
3.4.1 Site selection ...............................................................................................................37
3.4.2 Unpacking the unit ......................................................................................................37
3.4.3 Required tools and components ..................................................................................38
3.4.4 Supporting tools and components .............................................................................. 39
3.5 Installation .................................................................................................................................39
3.5.1 DC power supply .........................................................................................................39
3.5.2 Optional AC/DC power converter ................................................................................41
3.5.3 Connect the sample and other gas lines ...................................................................... 42
3.5.4 Maximum effective distance by communication protocol type ................................... 45
3.5.5 RS-485 serial port terminals ........................................................................................ 45
3.5.6 Installing and connecting to an analog modem card ................................................... 45
3.5.7 Connecting to the GC via the analog modem .............................................................. 46
3.5.8 Connecting directly to a PC using the GC’s Ethernet port ............................................ 47
3.5.9 Troubleshooting DHCP connectivity issues ................................................................. 50
3.5.10 Connecting directly to a PC using the GC’s serial port ..................................................51
3.5.11 Connecting directly to a PC using the GC’s wired Ethernet terminal ............................ 53
3.5.12 Assigning a static IP address to the GC .........................................................................55
3.5.13 Discrete digital I/O wiring ............................................................................................57
3.5.14 Analog input wiring .....................................................................................................63
3.5.15 Analog output wiring .................................................................................................. 67
3.6 Leak checking and purging for first calibration ...........................................................................72
3.6.1 Checking the GC for leaks ............................................................................................72
3.6.2 Purging carrier gas lines .............................................................................................. 73
3.6.3 Purging calibration gas lines ........................................................................................74
3.7 System startup .......................................................................................................................... 74
Chapter 4 Operation and maintenance .........................................................................................75
4.1 Warning and precautions ...........................................................................................................75
4.2 Start a two-point calibration ...................................................................................................... 75
4.3 Troubleshooting and repair concept .......................................................................................... 76
4.4 Routine maintenance ................................................................................................................ 76
4.4.1 Maintenance checklist .................................................................................................76
4.4.2 Routine maintenance procedures ............................................................................... 78
4.4.3 Precautions for handling PC assemblies .......................................................................78
4.4.4 General troubleshooting ............................................................................................. 78
4.4.5 Checking the GC for leaks ............................................................................................89
4.4.6 Valves ......................................................................................................................... 90
4.4.7 Detector maintenance ................................................................................................ 93
4.4.8 Removing the FID ........................................................................................................95
4.4.9 LSIV maintenance ....................................................................................................... 97
4.4.10 Methanator maintenance ..........................................................................................103
4.4.11 Measure vent flow .....................................................................................................105
4.4.12 Electrical components ...............................................................................................105
4.4.13 Factory settings for jumpers and switches .................................................................110
4.4.14 Communications .......................................................................................................111
4.4.15 Installing or replacing a FOUNDATION fieldbus module ............................................ 119
4.4.16 Analog inputs and outputs ........................................................................................ 126
4.4.17 Discrete digital inputs and outputs ............................................................................126
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4.4.18 Recommended spare parts ....................................................................................... 127
4.4.19 Upgrading the embedded software ...........................................................................127
Appendices and reference
Appendix A Local operator interface ............................................................................................. 129
A.1 Interface components for displaying and entering data ...........................................................129
A.1.1 Light emitting diode indicators ................................................................................. 129
A.1.2 LCD screen ................................................................................................................ 130
A.1.3 Keypad ......................................................................................................................130
A.2 Using the local operator interface ............................................................................................ 131
A.2.1 Start up ..................................................................................................................... 131
A.2.2 Navigating menus ..................................................................................................... 132
A.2.3 Navigating the screen ............................................................................................... 132
A.2.4 Editing numeric fields ................................................................................................134
A.2.5 Editing non-numeric fields ........................................................................................ 135
A.3 Screen navigation and interaction tutorial ............................................................................... 139
A.4 The LOI screens ........................................................................................................................145
A.4.1 The Chromatogram menu .........................................................................................147
A.4.2 The Hardware menu ..................................................................................................152
A.4.3 The Application menu ............................................................................................... 157
A.4.4 The Logs/Reports menu ............................................................................................ 162
A.4.5 The Control menu ..................................................................................................... 166
A.4.6 The Manage menu .................................................................................................... 170
A.5 Troubleshooting a blank LOI screen ......................................................................................... 172
Appendix B Carrier gas installation and maintenance .................................................................... 175
B.1 Carrier gas ............................................................................................................................... 175
B.2 Installation and line purging .................................................................................................... 176
B.3 Replacing carrier cylinder .........................................................................................................177
B.4 Calibration gas .........................................................................................................................177
Appendix C Recommended spare parts ......................................................................................... 179
C.1 Recommended spare parts for 700XA TCD analyzers ...............................................................179
C.2 Recommended spare parts for 700XA FID/TCD analyzers ........................................................ 180
C.3 Recommended spare parts for 700XA FID analyzers ................................................................ 181
Appendix D Shipping and long-term storage recommendations ....................................................183
Appendix E Engineering drawings ................................................................................................ 185
E.1 List of engineering drawings .................................................................................................... 185
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Introduction
1 Introduction
This section describes the contents and purpose of the 700XA Gas Chromatograph System
Reference Manual, a description of the Model 700XA system, an explanation of the theory
of operation, and a glossary of chromatograph terminology.
Use this section to get acquainted with the basic engineering of the 700XA.
1.1 Description of manual
The 700XA Gas Chromatograph System Reference Manual (P/N 3-9000-744) consists of
installation, operations, maintenance, and troubleshooting procedures.
1.2 System description
The 700XA is a high-speed gas chromatograph (GC) system that is engineered to meet
specific field application requirements based on typical hydrocarbon stream composition
and anticipated concentration of the selected components. In its standard configuration,
the 700XA gas chromatograph can handle up to eight streams: seven for sample streams
and one calibration stream.
Introduction
1
The 700XA system consists of two major parts: the analyzer assembly and the electronics
assembly. Depending upon the particular GC, there may also be a third, optional, assembly
called the sample conditioning system (SCS).
The 700XA’s electronics and hardware are housed in an explosion-proof enclosure that
meets the approval guidelines of various certification agencies for use in hazardous
environments. See the certification tag on the GC for specific details about agency
approvals.
1.2.1 Analyzer assembly
The analyzer assembly includes the columns, TCDs/FIDs, a preamplifier, a preamplifier
power supply, stream switching valves, analytical valves and solenoids. Additionally, the
700XA can be equipped with a liquid sample injection valve or a methanator.
For more information, see Section 2.1.2.
1.2.2 Electronics assembly
The electronics assembly includes the electronics and ports necessary for signal
processing, instrument control, data storage, personal computer (PC) interface, and
telecommunications. This assembly allows the user to use MON2020 to control the GC.
Refer to Section 2.2.2 for more details.
1
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Introduction
The GC-to-PC interface provides the user with the greatest capability, ease-of-use, and
flexibility. MON2020 can be used to edit applications, monitor operations, calibrate
streams, and display analysis chromatograms and reports, which can then be stored as
files on the PC’s hard drive or printed from a printer connected to the PC.
WARNING!
Do not use a PC or a printer in a hazardous area. Serial ports and Modbus communication links
are provided to connect the unit to the PC and to connect to other computers and printers in a
safe area. Failure to follow this warning may result in injury or death to personnel or cause
damage to the equipment.
1.2.3 Sample conditioning system (SCS)
The optional sample conditioning system is located between the process stream and the
sample inlet, which is often mounted below the GC. The standard SCS configuration
includes a stream switching system and filters.
1.3 Functional description
A sample of the gas to be analyzed is taken from the process stream by a sample probe
installed in the process line. The sample passes through a sample line to the SCS where it is
filtered or otherwise conditioned. After conditioning, the sample flows to the Analyzer
Assembly for separation and detection of the gas components.
The chromatographic separation of the sample gas into its components is accomplished in
the following manner. A precise volume of sample gas is injected into one of the analytical
columns. The column contains a stationary phase (packing) that is either an active solid or
an inert solid support that is coated with a liquid phase (absorption partitioning). The
sample gas is moved through the column by means of a mobile phase (carrier gas). The
selective retardation of the components takes place in the column, causing each
component to move through the column at a different rate. This separates the sample into
its constituent gases and vapors.
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.
Note
For additional information, see Section 1.4.
Output from the electronic assembly is normally displayed on a remotely located PC or a
printer. Connection between the GC and the PC can be accomplished via a direct serial
line, an optional ethernet cable, or via a Modbus-compatible communication interface.
Several chromatograms may be displayed via MON2020, with separate color schemes,
allowing the user to compare present and past data.
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Introduction
In most cases it is essential to use MON2020 to configure and troubleshoot the GC. The PC
may be remotely connected via ethernet, telephone, radio or satellite communications.
Once installed and configured, the GC can operate independently for long periods of time.
Gas chromatography process modelFigure 1-1:
1.4 Software description
The GC uses three distinct types of software. This enables total flexibility in defining the
calculation sequence, printed report content, format, type and amount of data for
viewing, control and/or transmission to another computer or controller assembly. The
three types are:
• Embedded GC firmware
• Application configuration software
• Maintenance and operations software (MON2020)
Introduction
1
The BOS and the Application configuration software are installed when the 700XA is
shipped. The application configuration is tailored to the customer’s process and shipped
on a CD-ROM. Note that the hardware and software are tested together as a unit before
the equipment leaves the factory. MON2020 communicates with the GC and can be used
to initiate site system setup (i.e., operational parameters, application modifications, and
maintenance).
1.4.1 Embedded GC firmware
The GC’s embedded firmware supervises operation of the 700XA through its internal
microprocessor-based controller; all direct hardware interface is via this control software.
It consists of a multi-tasking program that controls separate tasks in system operation, as
well as hardware self-testing, user application downloading, start-up, and
communications. Once configured, the 700XA can operate as a stand alone unit.
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Introduction
1.4.2 MON2020
MON2020 is a Windows-based program that allows the user to maintain, operate, and
troubleshoot a gas chromatograph. Individual GC functions that can be initiated or
controlled by MON2020 include, but are not limited to, the following:
• Valve activations
• Timing adjustments
• Stream sequences
• Calibrations
• Baseline runs
• Analyses
• Halt operation
• Stream/detector/heater 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
• LOI variable assignments (optional)
• Foundation Fieldbus variable assignments (optional)
Reports and logs that can be produced, depending upon the GC application in use,
include, but are not limited to, the following:
• Configuration report
• Parameter list
• Analysis chromatogram
• Chromatogram comparison
• Alarm log (unacknowledged and active alarms)
• Event log
• Various analysis reports
For a complete list of the GC functions, reports, and logs available through MON2020,
consult the software manual (P/N 2-3-9000-745).
MON2020 provides operator control of the 700XA, monitors analysis results, and inspects
and edits various parameters that affect 700XA operation. It also controls display and
printout of the chromatograms and reports, and it stops and starts automatic analysis
cycling or calibration runs.
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Introduction
After the equipment/software has been installed and the operation stabilized, automatic
operation can be initiated via an ethernet network.
1.5 Theory of operation
The following sections discuss the theory of operation for the GC, the engineering
principles and the concepts used.
Note
See Section 1.7 for definitions of the terminology used in the following explanations.
1.5.1 Thermal conductivity detector
One of the detectors available on the 700XA is a thermal conductivity detector (TCD) 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 thermistor is
designated the measurement element. See Figure 1-2 for a schematic diagram of the
thermal conductivity detector.
Introduction
1
Analyzer assembly with TCD bridgeFigure 1-2:
5
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Introduction
In the quiescent condition, prior to injecting a sample, both legs of the bridge are exposed
to pure carrier gas. In this condition, the bridge is balanced and the bridge output is
electrically nulled.
The analysis begins when the sample valve injects a fixed volume of sample into the
column. The continuous flow of carrier gas moves the sample through the column. As
successive components elute from the column, the temperature of the measurement
element changes.
The temperature change unbalances the bridge and produces an electrical output
proportional to the component concentration.
The differential signal developed between the two thermistors is amplified by the
preamplifier. Figure 1-3 illustrates the change in detector electrical output during elution of
a component.
Detector output during component elutionFigure 1-3:
In addition to amplifying the differential signal developed between the two thermistors,
the preamplifier supplies drive current to the detector bridge.
The signal is proportional to the concentration of a component detected in the gas
sample. The preamplifier provides four different gain channels as well as compensation for
baseline drift.
The signals from the preamplifier are sent to the electronic assembly for computation,
recording on a printer, or viewing on a PC monitor with MON2020.
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Introduction
1.5.2 Flame ionization detector
The other detector available for the 700XA is the flame ionization detector (FID). The FID
requires a polarization voltage and its output is connected to the input to a high
impedance amplifier that is called an electrometer. The burner uses a mixture of hydrogen
and air to maintain the flame. The sample of gas to be measured is also injected into the
burner. See Figure 1-4 for a schematic diagram of the FID.
Analyzer assembly with FID detector bridgeFigure 1-4:
Introduction
1
1.5.3 Liquid sample injection valve
The optional liquid sample injection valve (LSIV) converts a liquid sample into a gas sample
for GC analysis.
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Introduction
LSIV cross sectionFigure 1-5:
The LSIV penetrates the wall of the lower compartment and is held in place by a retaining
ring. The mounting arrangement is designed to ensure integrity of the flameproof
enclosure.
The outermost end houses an air-operated piston. Air at 60 PSI is directed by a solenoid
valve to either advance the stem to inject the sample or to retract the stem.
The next section houses sample input connections and stem sealing components. There
are two 1/8-inch O.D. tubing ports in this section; one port is for sample input, the other is
the exhaust for sample flow.
Within the enclosure cavity are the flash chamber components surrounded with insulating
covers. At working temperatures, the surfaces of these covers become very hot to the
touch.
The tip of the cylindrical flash chamber is the port where flashed sample is taken to the
oven system.
The port near the outer diameter of the end of the heated flash chamber block is the input
for carrier gas.
The flash chamber block is stainless steel and is surrounded by an insulating mounting
adapter. It houses the heater and an RTD.
1.5.4 Methanator
After all other components have been separated from the sample, carbon monoxide and
carbon dioxide, which are normally present in quantities too small to be detected by the
GC, can be sent through the optional methanator, where the two gases are combined with
hydrogen to make methane in a heat-generated catalytic reaction. The methanator is also
known as a methanizer or a catalytic converter.
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Introduction
1.5.5 Data acquisition
Every second, exactly 50 equally spaced data samples are taken (i.e., one data sample
every 20 milliseconds) for analysis by the controller assembly.
As a part of the data acquisition process, groups of incoming data samples are averaged
together before the result is stored for processing. Non-overlapping groups of N samples
are averaged and stored, and thus reduce the effective incoming data rate to 40/N
samples per second. For example, if N = 5, then a total of 40/5 or 8 (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
where PW is given in seconds. Allowable values of N are 1 to 63; this range corresponds to
PW values of 2 to 63 seconds.
The variable N is known as the integration factor. This term is used because N determines
how many points are averaged, or integrated, to form a single value. The integration of
data upon input, before storing, serves two purposes:
• The statistical noise on the input signal is reduced by the square root of N. In the
case of N = 4, a noise reduction of two would be realized.
• The integration factor controls the bandwidth of the chromatograph signal. It is
necessary to match the bandwidth of the input signal to that of the analysis
algorithms in the controller assembly. This prevents small, short-duration
perturbations from being recognized as true peaks by the program. It is therefore
important to choose a Peak Width that corresponds to the narrowest peak in the
group under consideration.
Introduction
1
1.5.6 Peak detection
For normal area or peak height concentration evaluation, the determination of a peak's
start point and end point is automatic. The manual determination of start and end points is
used only for area calculations in the Forced Integration mode. Automatic determination
of peak onset or start is initiated whenever Integrate Inhibit is turned off. Analysis is started
in a region of signal quiescence and stability, such that the signal level and activity can be
considered as baseline values.
Note
The controller assembly software assumes that a region of signal quiescence and stability will exist.
Having initiated a peak search by turning Integrate Inhibit off, the controller assembly
performs a point by point examination of the signal slope. This is achieved by using a
digital slope detection filter, a combination low pass filter and differentiator. The output is
continually compared to a user-defined system constant called Slope Sensitivity. A default
value of 8 is assumed if no entry is made. Lower values make peak onset detection more
sensitive, and higher values make detection less sensitive. Higher values (20 to 100) would
be appropriate for noisy signals, e.g. high amplifier gain.
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Introduction
Onset is defined where the detector output exceeds the baseline constant, but peak
termination is defined where the detector output is less than the same constant.
Sequences of fused peaks are also automatically handled. This is done by testing each
termination point to see if the region immediately following it satisfies the criteria of a
baseline. A baseline region must have a slope detector value less than the magnitude of
the baseline constant for a number of sequential points. When a baseline region is found,
this terminates a sequence of peaks.
A zero reference line for peak height and area determination is established by extending a
line from the point of the onset of the peak sequence to the point of the termination. The
values of these two points are found by averaging the four integrated points just prior to
the onset point and just after the termination points, respectively.
The zero reference line will, in general, be non-horizontal, and thus compensates for any
linear drift in the system from the time the peak sequence starts until it ends.
In a single peak situation, peak area is the area of the component peak between the curve
and the zero reference line. The peak height is the distance from the zero reference line to
the maximum point on the component curve. The value and location of the maximum
point is determined from quadratic interpolation through the three highest points at the
peak of the discrete valued curve stored in the controller assembly.
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 calculation accuracy and
eliminates the effects of variations in the integration factor on these calculations.
For calibration, the controller assembly may average several analyses of the calibration
stream.
1.6 Basic analysis computations
Two basic analysis algorithms are included in the controller assembly:
• Area Analysis – calculates area under component peak
• Peak Height Analysis – measures height of component peak
Note
For additional information about other calculations performed, see the MON2020 user manual.
1.6.1 Concentration analysis - response factor
10
Concentration calculations require a unique response factor for each component in an
analysis. These response factors may be manually entered by an operator or determined
automatically by the system through calibration procedures (with a calibration gas mixture
that has known concentrations).
Page 19
Introduction
The response factor calculation, using the external standard, is:
AR Fn=
Area
Cal
n
or
n
HR Fn=
H t
Cal
n
n
where
ARF
Area
Cal
Ht
n
HRF
n
n
n
n
area response factor for component “n” in area per mole percent
area associated with component “n” in calibration gas
amount of component “n” in mole percent in calibration gas
peak height associated with component “n” mole percent in calibration gas
peak height response factor for component “n”
Calculated response factors are stored by the controller assembly for use in the
concentration calculations, and are printed out in the configuration and calibration
reports.
Average response factor is calculated as follows:
k
∑
R F
i
RFAV Gn=
i=1
k
Introduction
1
where
RFAVG
n
RF
i
k number of calibration runs used to calculate the response factors
area or height average response factor for component “n”
area or height average response factor for component “n” from the calibration run
The percent deviation of new RF averages from old RF average is calculated in the following
manner:
R F
− R F
deviation =
new
R F
old
old
× 100
where the absolute value of percent deviation has been previously entered by the
operator.
1.6.2 Concentration calculation - mole percentage (without normalization)
Once response factors have been determined by the controller assembly or entered by the
operator, component concentrations are determined for each analysis by using the
following equations:
11
Page 20
Introduction
CON Cn=
Area
AR F
n
or
n
CON Cn=
H t
HR F
n
n
where
ARF
n
Area
CONC
Ht
n
HRF
n
n
Area response factor for component “n” in area per mole percent.
Area associated with component “n” in unknown sample.
Concentration of component “n” in mole percent.
n
Peak height associated with component “n” mole percent in unknown sample.
Peak height response factor for component “n”.
Component concentrations may be input through analog inputs 1 to 4 or may be fixed. If a
fixed value is used, the calibration for that component is the mole percent that will be used
for all analyses.
1.6.3 Concentration calculation in mole percentage (with normalization)
The normalized concentration calculation is:
CON C
∑
i=1
k
CON C
n
× 100
i
CONC Nn=
where
CONCN
n
CONC
i
CONC
n
k Number of components to be included in the normalization.
Note
The average concentration of each component will also be calculated when data averaging is
requested.
1.7 Glossary
Auto Zero Automatic zeroing of the TCD preamplifier can be configured to take
Normalized concentration of component “n” in percent of total gas concentration.
Non-normalized concentration of component “n” in mole percent for each “k”
component.
Non-normalized concentration of component “n” in mole percent.
place at any time during the analysis if the component is not eluting or
the baseline is steady.The FID will auto zero at each new analysis run
12
Page 21
Introduction
and can be configured to auto zero anytime during the analysis if the
component is not eluting or the baseline is steady. The TCD is only
auto zeroed at the start of a new analysis.
Baseline Signal output when there is only carrier gas going across the
detectors. In a chromatogram you should only see Baseline when
running an analysis without injecting a sample.
Carrier gas The gas used to push the sample through the system during an
analysis. In C6+ analysis we use Ultra Pure (zero grade) Carrier Gas for
the carrier. This gas is 99.995 percent pure.
Chromatogram A permanent record of the detector output. A chromatogram is
obtained from a PC interfaced with the detector output through the
controller assembly. A typical chromatogram displays all component
peaks, and gain changes. It may be viewed in color as it is processed
on a PC VGA display. Tick marks recorded on the chromatogram by
the controller assembly 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.
CTS Clear to send.
DCD Data carrier detect.
DSR Data set ready.
DTR Data terminal ready.
FID Flame ionization detector. The optional FID may be used in place of a
TCD for the detection of trace compounds. The FID requires a
polarization voltage and its output is connected to the input to a high
impedance amplifier, an electrometer. The sample of gas to be
measured is injected into the burner with a mixture of hydrogen and
air to maintain the flame.
LSIV Liquid sample injection valve. The optional LSIV is used to convert a
liquid sample to a gas sample by vaporizing the liquid in a heated
chamber, then analyzing the flashed sample.
Methanator The optional methanator, also known as a catalytic converter,
transforms otherwise undetectable carbon dioxide and/or carbon
monoxide into methane by adding hydrogen and heat to the sample.
Response factor Correction factor for each component as determined by the following
calibration:
RF =
Calibration Concentration
RawArea
Retention time Time, in seconds, that elapses between the start of analysis and the
sensing of the maximum concentration of each component by the
detector.
RI Ring indicator.
RLSD Received line signal detect. A digital simulation of a carrier detect.
RTS Request to send.
Introduction
1
13
Page 22
Introduction
RxD, RD, or S
Receive data, or signal in.
in
TCD Thermal conductivity detector. A detector that uses the thermal
conductivity of the different gas components to produce an
unbalanced signal across the bridge of the preamplifier. The higher
the temperature, the lower the resistance on the detectors.
TxD, TD, or S
Transmit data, or signal out.
out
14
Page 23
Equipment description and specifications
2 Equipment description and
specifications
Use the following sections to reference the 700XA equipment description or
specifications.
2.1 Equipment description
The 700XA consists of a copper-free aluminum explosion-proof chamber, and a front panel
assembly. The chamber is divided into two compartments that together house the GC’s
major components. This unit is designed for hazardous locations.
700XA gas chromatographFigure 2-1:
Equipment description and specifications
2
2.1.1 Front panel assembly
The front panel assembly is located on the front section of the lower enclosure and
consists of a removable, explosion-proof panel that shields either a switch panel or a local
operator interface (LOI).
15
Page 24
Equipment description and specifications
The switch panel
The switch panel contains a network of on/off switches that allow you to manually control
the GC’s stream and analytical valves.
8-stream switch panel (left) and 18-stream switch panel (right)Figure 2-2:
There are two types of switch panels: 8-stream and 18-stream. The 8- stream switch panel
is the standard panel, and is used when the GC has only one heater/solenoid board
installed; if two heater/solenoid boards are installed, then the 18-stream switch panel is
used.
Valve switch from switch panel set to “OFF”Figure 2-3:
A valve has the following three operational modes:
• AUTO - The valve turns on and off according to the Timed Events table that is
accessible through MON2020. To set a valve to AUTO mode, set its switch on the
switch panel to the “up” position.
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Page 25
Equipment description and specifications
• OFF - The valve turns off and remains off until the operational mode is changed. To
set a valve to OFF mode, set its switch on the switch panel to the “center”
position—that is, the switch is neither flipped “up” nor “down”.
• ON - The valve turns on and remains on until the operational mode is changed. To
set a valve to ON mode, set its switch on the switch panel to the “down” position.
Equipment description and specifications
Status LEDs (Top of switch panel)Figure 2-4:
The switch panels also contain the following status lights that allow you to monitor the
GC’s condition:
• Working - Turns green when the GC is in analysis mode.
• Unack. Alarm - Turns yellow if there is an unacknowledged alarm.
• Active Alarm - Turns red if there is an active alarm.
FID/FPD Status LEDFigure 2-5:
2
• FID/FPD - The 18-stream switch panel contains a FID or FPD status LED that can
indicate the following:
- A green light means the flame has ignited.
- A flashing yellow light means an attempt is being made to ignite the flame.
- A red light means the flame as gone out or that the FID or FPD is over-
temperature.
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Equipment description and specifications
• CPU - Green light blinks continuously while the GC is running.
• Valves - Turns green if the valves are functioning automatically; turns red if the
valves’ automatic settings have been overridden.
Note
During GC start up, all LEDs turn on for approximately ten seconds.
The local operator interface
The optional local operator interface (LOI) gives you more in-depth control over the GC’s
functions than does the switch panel. It has a high resolution color display that is touch key
activated and allows you to operate a 700XA GC without a laptop or a PC.
Status LEDs (Bottom of switch panel)Figure 2-6:
The local operator interfaceFigure 2-7:
The LOI includes the following features:
• Color LCD with VGA (640 x 480 pixels) resolution.
• ASCII text and graphics modes.
• Adjustable auto-backlighting.
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Equipment description and specifications
• 8 infrared-activated touch screen keys that eliminate the requirement for a
magnetic pen.
• Complete GC status, control and diagnostics, including full chromatogram display.
See Appendix A for more information about operating the LOI.
Equipment description and specifications
2.1.2 Upper compartment
The upper compartment contains the following components:
• Valves. There are two types of XA valves: 6-port and 10-port. A 700XA can have a
maximum of four XA valves consisting of any combination of the two types.
• Column module. Either capillary or micro-packed.
• Thermal conductivity detector (TCD). The 700XA has a minimum of one TCD and a
maximum of two TCDs.
• Two heating elements: a “top hat” heater and a column heater.
• One temperature switch for each heating element. The switch turns off its
heating element if the heating element reaches 257° F (160° C).
• Pressure switch. The pressure switch activates when the carrier pressure falls below
a predetermined set point. When activated, the switch triggers a general alarm that
displays on the front panel or LOI and in MON2020.
• Flame ionization detector (FID). The optional FID, which detects trace levels of
hydrocarbons, can be used in place of one TCD.
• Flame photometric detector (FPD). The optional FPD, which detects trace levels of
sulphur compounds, can be used in place of a TCD. Installed as a "side car"
component. For more information, refer to the FPD for Gas Chromatographs
Hardware Reference Manual.
• Methanator. The methanator, or catalytic converter, is an optional component that
converts otherwise undetectable carbon dioxide and/or carbon monoxide into
methane by adding hydrogen and heat to the sample.
• Liquid sample injection valve (LSIV). The optional LSIV is used to vaporize a liquid
sample, thereby expanding the GC’s capability to measure liquids.
2
2.1.3 Lower compartment
The lower compartment consists of the following components:
• Backplane. The backplane is the GC’s central printed circuit board (PCB). Its main
function is as a connection point for the GC’s specialized plug-in PCBs. The
backplane also hosts connections for analog outputs and analog inputs, serial ports
and an Ethernet port.
• Card cage. The card cage holds the specialized PCBs that plug into the backplane.
The following PCBs are housed in the card cage:
- Preamp board
- CPU board
- Base I/O board
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Page 28
Equipment description and specifications
- Heater/Solenoid board
The card cage also has four additional slots for the following optional PCBs:
- A second preamp board
- A second heater/solenoid board
- Two optional communications boards
The explosion-proof housing should not be opened when the unit is exposed to an
explosive environment. If access to the explosion-proof housing is required, take
precautions to ensure that an explosive environment is not present. Failure to do so
may result in injury or death to personnel or cause damage to the equipment.
• Optional AC/DC power supply.
WARNING!
See power supply label prior to connection. Check the unit power design to determine if
it is equipped for AC or DC power. Applying 110/220 VAC to a DC power input unit will
severely damage the unit. Failure to do so may result in injury or death to personnel or
cause damage to the equipment.
WARNING!
Note
The 700XA CSA-certified unit is equipped with 3/4-inch NPT-thread adapters.
2.1.4 Mechanical pressure regulators
The mechanical pressure regulatorsFigure 2-8:
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Page 29
Equipment description and specifications
The mechanical pressure regulators and gauges are used to set and monitor the pressure
of the carrier gas flow through the GC's columns, as well as the pressure of the FID air and
fuel (H2).
The regulators and gauges are located beneath the GC.
2.2 Equipment specifications
2.2.1 Utilities
Use the following table to determine the utility specifications.
Type Specification
Unit dimensions
• Basic unit envelope
W - 15.2” (387 mm)
H - 41.5” (1054 mm)
D - 19.2” (488 mm)
• Wall mount
W - 18.2” (463 mm)
H - 41.5” (1054 mm)
D - 19.2” (488 mm)
• Pole mount
W - 18.2” (463 mm)
H - 41.5” (1054 mm)
D - 25.0” (635 mm)
• Floor mount
W - 18.2” (463 mm)
H - 58.0” (1470 mm)
D - 19.2” (488 mm)
Equipment description and specifications
2
Note
Allow 14” (360 mm additional) clearance for removal of dome.
Unit weight • Wall mount - 110 lbs (59 kg)
• Pole mount - 135 lbs (61 kg)
• Floor mount - 180 lbs (82 kg)
Tubing • 316 stainless steel
• 316 stainless steel and Kapton® in contact with sample
• Sulfinert® steel (optional)
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Page 30
Equipment description and specifications
Type Specification
Mounting • Floor mount
Power • 24V DC standard (21-30 V DC operating voltage range); MAX 150 watts
Instrument air Not required; optional for valve actuation, minimum pressure of 90 psig
Environment • Hazardous area certified: -20o C to 60o C (-4o F to 140o F)
Approvals
• Pole mount:
- 2” (60.3 mm)
- 3” (89.0 mm)
- 4” (114.3 mm)
• Direct wall mount
• (optional) 100-120/240 V AC; 50-60 Hz
Note
Voltage range includes line voltage variations.
• 0 to 95% RH (non-condensing)
• Indoor/outdoor
• Pollution - degree 2 (The unit can withstand some non conductive environ-
mental pollutants e.g., humidity.)
FOR USE IN HAZARDOUS LOCATIONS:
• For Canada: Class I, Zone 1, EX d IIC T6, Enclosure Type 4 Class I, Division 1,
Group B, C and D.
• For USA: Class I, Zone 1, EX d IIC T6, Enclosure Type 4 Class I, Division 1, Group
B, C and D.
2.2.2 Electronic hardware
Use the following table to determine the electronic hardware specifications:
Type Specification
Rating Division 1; no purge required
Communication
ports
Optional modem 56K Baud Telephone
3 configurable Modbus ports that support RS-232/422/485 protocols; 2 optional ports in expansion slots; 9-pin RS-232 port.
Note
The maximum number of simultaneous Modbus TCP/IP connections from
Modbus Master is 10.
22
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Type Specification
Analog inputs 2 connectors on the backplane, isolated
Standard analog
outputs
Optional analog
outputs
Discrete digital inputs
Discrete digital outputs
Solenoid Driver
board
Transient protection Over-voltage category II
6 connectors on the backplane, isolated
8 connectors on optional expansion boards, isolated
5 connectors on the backplane
5 relay “Form C” contacts on Phoenix connectors on the backplane. Relay
contact rating 24 VDC nominal @ 1 Amp
Maximum current output:
Channels 1 - 8: Maximum rating is 17 W. Each channel can drive 2.12 W or
88.4 mA at 24 VDC.
Channel 9 - 12: Maximum rating is 17 W. Each channel can drive 4.24 W or
176.8 mA at 24 VDC.
Equipment description and specifications
Equipment description and specifications
2
2.2.3 Airless analytical oven
The following table lists the specifications for the oven assembly.
Type Specification
Valves 6-port and 10-port XA valves; piston-operated diaphragms with pneumatic
actuation
Columns Max of 90 ft (27.4 m) of micro-packed columns; 1/16-inch
(1.6-mm) outside diameter
or
300 ft (91.4 m) of capillary columns
Solenoid actuation • 24 VDC
• Max 120 psi
Temperature control
• 24 VDC
• 2 heaters
• 2 optional heaters
• Max oven operating temperature of 150° C (302° F)
2.2.4 Software
The following table lists the specifications for the GC’s software.
Type Specification
Software Windows-based MON2020.
23
Page 32
Equipment description and specifications
Type Specification
Firmware Embedded firmware. Can be upgrade with MON2020.
Methods 4 Timed Event tables and 4 Component Data tables assignable to each stream.
Peak Integration • Fixed time or auto slope and peak identification.
• Update retention time upon calibration or during analysis.
2.2.5 Corrosion protection
Type Specification
Enclosure Material Copper-free and aluminum-coated with indus-
Process Wetted Materials Stainless steel; if the function of an item ex-
Electronics All electronic circuit boards are tropicalized with
trial grade powder coat suitable for high humidity and salt-laden environments.
cludes the use of stainless steel, such as the
glass rotameter tubes, materials that are resistant to corrosion are used.
a clear conformal coating.
2.2.6 Archived Data Storage Capabilities
Maximum Number of Re-
Type
Analysis Results 31744 88 days with 4 minute cycle
Final Calibration Results 370 1 year of Final Calibration re-
Calibration Results 100
Final Validation Results 370 1 year of Final Validation results
Validation Results 100
Analysis Chromatograms 1703 Approximately 4.5 days assum-
Final Calibration Chromatograms
Final Validation Chromatograms
Protected Chromatograms 100 User -selectable
Hourly Averages (Up to 250**
variables)
cords Remarks
370 1 year of Final Calibration Chro-
370 1 year of Final Validation Chro-
2400 100 days
time
sults
ing 4 minute cycle time
matograms*
matograms*
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Equipment description and specifications
Maximum Number of Re-
Type
Daily Averages (Up to
250**variables)
Weekly Averages (Up to 250**
variables)
Monthly Averages (Up to
250** variables)
Variable Averages (Up to
250** variables)
Every run (Up to 250** variables)
Alarm Logs 1000
Event Logs 1000
cords Remarks
365 1 Year
58 1 Year
12 1 Year
2360
2360
* The GC can store final calibration or final validation chromatograms for up to a year,
provided that no more than one calibration or validation is run per day, and the cycle time
is less than 15 minutes. If the cycle time exceeds 15 minutes, the oldest final calibration or
validation chromatograms will be deleted to make room for newer ones.
Equipment description and specifications
2
** You can have a total of up to 250 averages of all types, including Hourly, 24 Hour,
Weekly, Monthly, Variable and Every Run averages.
25
Page 34
Equipment description and specifications
26
Page 35
3 Installation and setup
This section provides instructions for installing and commissioning the 700XA.
Installation and setup
Installing a 700XA involves the following steps:
1. Observing precautions and warnings.
2. Planning site location and mounting arrangement.
3. Obtaining supplies and tools.
4. Mounting the unit.
5. Installing GC wiring.
6. Installing GC sample and gas lines.
7. Purging carrier gas lines.
8. Purging calibration lines.
9. Performing leak checks.
10. Starting up GC system.
3.1 Precautions and warnings
WARNING!
Install and operate all equipment as designed and comply with all safety requirements. The
seller does not accept any responsibility for installations of the GC, 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.
Installation and setup
3
WARNING!
If the unit is not operated in a manner recommended by the manufacturer, the overall safety
could be impaired.
WARNING!
The unit is intended to be connected to supply mains by qualified personnel in accordance with
local and national codes.
WARNING!
A suitable APPROVED switch and fuse or a circuit breaker shall be provided to facilitate the
disconnection of mains power.
27
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Installation and setup
WARNING!
The unit is required to be used in a well ventilated area.
WARNING!
All gas connections must be properly leak tested at installation.
WARNING!
No user replaceable part inside except a few parts that are only allowed to be accessed by
trained service personnel.
WARNING!
Observe and comply with all precautionary signs posted on the GC. Failure to do so may result
in injury or death to personnel or cause damage to the equipment
WARNING!
If you plan to place the GC in a sealed shelter, always vent the GC to atmosphere with ¼-inch
tubing or larger. This will prevent the build up of H2 and sample gas.
WARNING!
Exit ports may discharge dangerous levels of toxic vapors; use proper protection and a suitable
exhaust device.
CAUTION!
Waste electrical and electronic products must not be disposed of with household waste. Please
recycle where facilities exist. Check with your local authority or retailer for recycling advice.
Note
The 700XA is CSA-certified and ATEX-certified. See the certification tag on the GC for specific details
about its agency approvals.
The following special conditions for safe use must be met:
Note
When installed, the equipment shall pass an electrical strength test of (1000 + 2 Un) V, rms applied
for at least 10 seconds up to a maximum of 60 seconds.
28
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Installation and setup
Note
When the vapor regulators and flow switches are fitted they must be suitably certified with the
ratings Ex d IIC Gb T5/T6/T4 and for a minimum ambient temperature range Ta = -20°C to +60°C.
Note
Where right angle bend cable adaptors are used they shall be appropriately certified and shall
interface with enclosures via appropriate certified barrier glands.
Installation and setup
3.1.1 Installation considerations
Consider the following before installing the GC:
1. Anchor the GC solidly before performing electrical connections.
Several options for mounting the unit are covered in this section. The GC is heavy
and the potential for damage to equipment or personnel is high.
2. Ensure that the connections to the enclosure meet local standards.
3. Use approved seals: either cable glands or conduit seals.
a. Install conduit seals within three inches of the enclosure.
b. Seal unused openings with approved blanks (plugs).
Threads for these openings are M32 x 1.5.
4. Remove any packing materials before powering up the unit.
5. Do not power up an open unit unless the surrounding area is certified nonhazardous.
6. Printers and most laptop computers cannot be used in hazardous areas.
3.2 XA mounting arrangements
3
The 700XA can be installed in one of the following mounting arrangements:
• Wall mount
• Pole mount
• Floor mount
When putting a unit into its final position, be careful to avoid damaging any of the external
components or their attachments. Due to the size, weight, and shape of the GC, at least
two people are required to safely mount the unit. Also, make sure you understand the
installation procedure before handling the unit, and collect the appropriate tools
beforehand.
29
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Installation and setup
3.2.1 Wall mount
The simplest mounting arrangement is the wall mount. If ‘Wall Mount’ is specified on the
sales order, the unit will be shipped with a wall mount installation kit. Four locations on the
mounting ears are available for support.
1. The unit is most easily mounted if a pair of 7/16-inch dia. (10 mm dia.) bolts with
washers are pre-installed on the wall from which to hang the unit before installing
the final pair of bolts.
The first pair of bolts should be approximately 41.625 inches (1055 mm) off the
ground, and 13.625 inches (346 mm) apart. Each bolt should have 5/8-inches (16
mm) of bare length projecting. A second pair of holes 3.56 inches (90.5 mm) above
the first will be required.
CAUTION!
Until all bolts are tight, the unit should be supported to prevent unforeseen accidents.
Wall mountFigure 3-1:
30
Page 39
2. Maneuver the GC so that the notches in the mounting ears can be placed over the
bolts on the wall and then place the washers over the bolts.
3. Install the second pair of bolts with washers and then tighten all the bolts.
3.2.2 Pole mount
Installation and setup
The pole mount arrangement uses an additional plate and spacers to allow the necessary
clearance for nuts. All hardware will be provided if ‘Pole Mount’ is specified on the sales
order.
Pole mountFigure 3-2:
Installation and setup
3
1. Use the u-bolt to firmly install the large plate on the pole about 44 inches (1120
mm) above the ground.
2. Install the long bolts and spacers.
3. Place nuts and washers on the lower bolts.
4. Install the small plate just tightly enough to hold its position, with the small plate’s
u-bolt about 6.875 inches (174.625 mm) below the large plate’s U-bolt.
5. Hold the matching spacer in place with the bolts installed loosely.
6. Orient the unit so that the notches in the mounting ears can be placed over the
lower bolts on the plate and then add the washers and nuts.
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Installation and setup
7. Place the nuts with washers on the upper bolts and then tighten all bolts.
WARNING!
Until all bolts are tight, the unit should be supported to prevent unforeseen accidents.
8. Adjust the lower bracket to align the bolts with the plate. Tighten the bolts.
3.2.3 Floor mount
If ‘Floor Mount’ is specified in the sales order, the arrangement comes pre-assembled with
the GC. The arrangement includes an additional support stand that is intended to be
anchored to a floor or an instrument pad. The base rails have holes that are 13.625 inches
(346 mm) apart, side to side, and 16.75 inches (425.5 mm) apart front to back. The holes
are ½-inch in diameter and will accept up to 7/16-inch (or 10 mm) bolts.
Floor mountFigure 3-3:
32
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3.3 Gas chromatograph wiring
3.3.1 Power source wiring
Follow these precautions when installing power source wiring:
• All wiring, as well as circuit breaker or power disconnect switch locations, must
conform to the CEC or NEC; all local, state, or other jurisdictions; and company
standards and practices.
• Provide single-phase, three-wire power at 120 or 240 VAC, 50-60 Hertz.
Note
If you do not have a single phase, three-wire AC power source, you must purchase an isolation
transformer. Refer to Drawing #CE19492E1 at the back of the manual for more information.
• Locate in a safe area.
• Provide the GC and any optionally installed devices with one 15-amp circuit breaker
for protection.
Installation and setup
Installation and setup
3
CAUTION!
15 amps is the maximum current for 14 AWG (wire).
• Ensure that the 24 VDC input power is compliant with the Separated Extra-Low
Voltage (SELV) standard by suitable electrical separation from other circuits.
• Use multi-stranded copper conductor wire according to the following
recommendations:
- For power feed distances up to 250 feet (76 meters), use 14 AWG (American
Wire Gauge) (18 Metric Wire Gauge), stranded.
- For power feed distances 250 to 500 feet (76 to 152 meters), use 12 AWG (25
Metric Wire Gauge), stranded.
- For power feed distances 500 to 1000 feet (152 to 305 meters), use 10 AWG (30
Metric Wire Gauge), stranded.
- Cable entries are M32 in accordance with ISO 965.
3.3.2 Signal wiring
Follow these general precautions for field wiring digital and analog input/output (I/O)
lines:
• Metal conduit or cable (according to local code) used for process signal wiring must
be grounded at conduit support points because intermittent grounding helps
prevent the induction of magnetic loops between the conduit and cable shielding.
33
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Installation and setup
• All process signal wiring should be of a single, continuous length between field
devices and the GC. If, however, the length of the conduit runs require that multiple
wiring pulls be made, the individual conductors must be interconnected with
suitable terminal blocks.
• Use suitable lubrication for wire pulls in conduit to prevent wire stress.
• Use separate conduits for AC voltage and DC voltage circuits.
• Do not place digital or analog I/O lines in the same conduit as AC power circuits.
• Use only shielded cable for digital I/O line connections.
- Ground the shield at only one end.
- Shield-drain wires must not be more than two AWG sizes smaller than the
conductors for the cable.
• When inductive loads (relay coils) are driven by digital output lines, the inductive
transients must be diode-clamped directly at the coil.
• Any auxiliary equipment wired to the GC must have its signal common isolated from
earth/chassis ground.
WARNING!
Any loop of extra cable left for service purposes inside the GC purged housing must not be
placed near the conduit entry for AC power. This applies to all digital and analog I/O lines
connecting to the GC. If the above precaution is not followed, the data and control signals to
and from the GC can be adversely affected.
3.3.3 Electrical and signal ground
Follow these general precautions for grounding electrical and signal lines:
• For shielded signal conducting cables, shield-drain wires must not be more than two
AWG sizes smaller than the conductors for the cable. Shielding is grounded at only
one end.
• Metal conduit used for process signal wiring must be grounded at conduit support
points (intermittent grounding of conduit helps prevent induction of magnetic
loops between the conduit and cable shielding).
• A single-point ground must be connected to a copper-clad, 10-foot long, 3/4-inch
diameter steel rod, which is buried, full-length, vertically into the soil as close to the
equipment as is practical.
Note
The grounding rod is not furnished.
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Installation and setup
Interior ground lug, lower enclosureFigure 3-4:
• Resistance between the copper-clad steel ground rod and the earth ground must
not exceed 25 Ohms.
• On ATEX-certified units, the external ground lug must be connected to the
customer’s protective ground system via 9 AWG (6mm2) ground wire. After the
connection is made, apply a non-acidic grease to the surface of the external ground
lug to prevent corrosion.
• The equipment-grounding conductors used between the GC and the copper-clad
steel ground rod must be sized according to your local regulations, the following
specifications apply in the US.
Installation and setup
3
Length Wire
15 ft. (4.6 m) or less 8 AWG, stranded, insulated copper
15 to 30 ft. (4.6 to 9.1 m) 6 AWG, stranded, insulated copper
30 to 100 ft. (9.1 to 30.5 m) 4 AWG, stranded, insulated copper
• All interior enclosure equipment-grounding conductors must be protected by metal
conduit.
• External equipment that is connected to the GC should be powered via isolation
transformers to minimize the ground loops caused by the internally shared safety
and chassis grounds.
3.3.4 Electrical conduit
Follow these general precautions for conduit installation:
• Conduit cutoffs must be cut at a 90-degree angle. Cutoffs must be made by a cold
cutting tool, hacksaw, or by some other approved means that does not deform the
conduit ends or leave sharp edges.
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Installation and setup
• All conduit fitting-threads, including factory-cut threads, must be coated with a
metal-bearing conducting grease prior to assembly.
• Temporarily cap the ends of all conduit runs immediately after installation to
prevent accumulation of water, dirt, or other contaminants. If necessary, swab out
conduits prior to installing the conductors.
• Install drain fittings at the lowest point in the conduit run; install seals at the point of
entry to the GC explosion-proof housing to prevent vapor passage and
accumulation of moisture.
• Use liquid-tight conduit fittings for conduits exposed to moisture.
When a conduit is installed in hazardous areas, follow these general precautions for
conduit installation:
• All conduit runs must have a fitting, which contains explosion-proof sealing
(potting) located within three inches from the conduit entrance to the explosionproof housing.
• The conduit installation must be vapor tight, with threaded hub fittings, sealed
conduit joints and gaskets on covers, or other approved vapor-tight conduit fittings.
WARNING!
Observe all precautionary signs posted on the equipment. Consult your company's policies and
procedures and other applicable documents to determine wiring and installation practices that
are appropriate for hazardous areas. Failure to do so may result in injury or death to personnel
or cause damage to the equipment.
3.3.5 Sample system requirements
Observe the following guidelines for installing GC sample systems:
Line Length If possible, avoid long sample lines. In case of a long sample line, flow veloci-
ty can be increased by decreasing downstream pressure and using by-pass
flow via a speed loop.
CAUTION!
Stream switching requires a sample pressure of 20 psig.
Sample Line Tubing
Material
• Use Silco tubing for H2S streams; for all other applications use stainless
steel tubing.
• Ensure tubing is clean and free of grease.
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Installation and setup
Dryers and Filters Use small sizes to minimize time lag and prevent back diffusion.
• Install a minimum of one filter to remove solid particles. Most applica-
tions require fine-element filters upstream of the GC. The GC includes a
2-micron filter.
• Do use ceramic or porous metallic type filters. Do not use cork or felt fil-
ters.
Note
Install the probe/regulator first, immediately followed by the coalescing filter and then the membrane filter. See Appendix B for a recommended natural gas installation.
Installation and setup
3
Pressure Regulators and Flow Controllers
Pipe Threads and
Dressings
Valving • Install a block valve downstream of sample takeoff point for mainte-
3.4 Preparation
Your GC was started and inspected before it left the factory. Program parameters were
installed and documented in the GC Config Report furnished with your gas
chromatograph.
3.4.1 Site selection
Install the GC as close as possible to the sample system but allow for adequate access
space for maintenance tasks and adjustments. Allow a minimum of 14 inches (36 cm) in
front for enclosure opening and access. Allow a minimum of 14 inches (36 cm) above the
top of the dome enclosure for dome removal and access.
• Use stainless steel wetted materials.
• Should be rated for sample pressure and temperature.
Use Teflon tape. Do not use pipe thread compounds or pipe dope.
nance and shutdown.
• The block valve should be a needle valve or cock valve type, of proper
material and packing, and rated for process line pressure.
Ensure that exposure to radio frequency (RF) interference is minimal.
3.4.2 Unpacking the unit
1. Unpack the equipment:
• 700XA
• CD-ROM containing software and manuals.
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Installation and setup
Note
The serial number for MON2020 is located on the back of its CD-ROM case.
2. If your GC is configured with an FID, remove the vent plug from the FID outlet.
The vent plug has a tag attached to it that reads “REMOVE VENT PLUGS PRIOR TO
OPERATION”. Failure to remove the cap could result in a performance failure or in
damage to the detector.
Installation and startup 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 describing the nature and extent of the
damage and forward this report immediately to your Emerson Process Management
representative. Include the GC's model number in the report. Disposition instructions will
be provided as soon as possible. If you have any questions regarding the claim process,
contact your Emerson Process Management representative for assistance.
3.4.3 Required tools and components
You will need the following tools and components to install the 700XA:
• Zero grade carrier gas:
- 99.995% pure
- Less than 5 ppm water
- Less than 0.5 ppm hydrocarbons
• High pressure dual-stage regulator for the carrier gas cylinder:
- High side up to 3000 psig
- Gauge (psig)
- Low side capable of controlling pressure up to 150 psig
• Calibration standard gas with correct number of components and concentrations.
• Dual-stage regulator for the calibration gas cylinder with a low pressure side capable
of controlling pressure up to 30 psig.
• Sample probe regulator (fixture for procuring the stream, or sample gas for
chromatographic analysis).
• Coalescing filter.
• Membrane filter.
• Eighth-inch stainless steel tubing:
- For connecting calibration gas to the GC
- For connecting carrier gas to the GC.
- For connecting stream gas to the GC.
• Heat tracing, as required, for sample transport and calibration lines.
• Miscellaneous tube fittings, tubing benders, and tubing cutter.
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• 14 AWG (American Wire Gauge), 18 MWG (Metric Wire Gauge) or larger electrical
wiring and conduit to provide 120 or 240 volts AC, single phase, 50 to 60 Hertz,
from an appropriate circuit breaker and power disconnect switch. See guidelines in
Section 3.3.
• Digital volt-ohm meter with probe-type leads.
• Flow measuring device.
• Open-end wrenches sized 1/4-inch, 5/16-inch, 7/16-inch, 1/2-inch, 9/16-inch and
5/8-inch.
• Torque wrench.
3.4.4 Supporting tools and components
WARNING!
Do not use a PC or a printer in a hazardous area. Serial port and Modbus communications links
are provided to connect the unit to the PC and to connect to other computers and printers in a
safe area. Failure to follow this warning may result in injury or death to personnel or cause
damage to the equipment.
Installation and setup
Installation and setup
3
Supporting tools and components include:
• Use a Windows-based PC and either a direct or remote communications connection
to interface with the GC. See the MON2020 user manual for more information on
specific PC requirements.
• The GC comes with an ethernet port on the back plane factory-wired with an RJ-45
connector. Refer to Section 3.5.8 for more information.
3.5 Installation
Note
CPU boards are switched off before shipping to preserve the board's battery. Before installing into
the GC, be sure to switch the CPU board on.
3.5.1 DC power supply
WARNING!
Ensure that the 24 VDC input power source is switched OFF before connecting the wires. Also,
ensure that the 24 VDC input power is SELV compliant by suitable electrical separation from
other circuits. Failure to follow this warning may result in injury or death to personnel or cause
damage to the equipment.
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Installation and setup
CAUTION!
Check the unit prior to wiring to determine if it is equipped for DC power. Failure to observe
this precaution may damage equipment.
To connect a 24 VDC power source to the GC, do the following:
1. Locate the plug-together termination block inside the electronics enclosure.
24 VDC power connection on the back planeFigure 3-5:
40
2. Bring the two leads in through one of the two possible entries on the lower
compartment. Connect to the termination plug provided with the unit. See
Appendix F, drawing #DE- 20993.
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Installation and setup
Figure 3-6:
Location of entries for wiring on the under side of the lower
enclosure
Use the following table for the DC power wiring details:
Attribute Wire Color
+ (positive) red
– (negative) black
Installation and setup
3
Note
Do not disconnect the factory-installed ground wire.
3. The backplane board that connects to the 24 VDC is protected from lead reversal by
the use of blocking diodes.
If the red (+) and black (-) leads are inadvertently reversed, no damage will occur;
however, the system will not have power.
4. Connect the DC power leads to the power disconnect switch that should be properly
fused. The recommended fuse size is 8 amps.
3.5.2 Optional AC/DC power converter
WARNING!
Check the unit prior to wiring to determine if it is equipped for optional AC power. Failure to
follow this warning may result in injury or death to personnel or cause damage to the
equipment.
To connect a 120 or 240 VAC power source to the GC, do the following:
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Installation and setup
1. Locate the plug-together termination block inside the electronics enclosure, atop
the power supply and adjacent to the card cage.
AC/DC termination blockFigure 3-7:
WARNING!
Do not connect the AC power leads without first ensuring that AC power source is
switched OFF. Failure to follow this warning may result in injury or death to personnel or
cause damage to the equipment.
CAUTION!
Do not apply electrical power to the GC until all interconnections and external signal
connections have been verified, and proper grounds have been made. Failure to observe
this precaution may cause damage to equipment.
AC wiring is usually colored as:
Label Wire Color
Hot (H) brown or black
Neutral (N) blue or white
Ground (G) green with yellow tracer or green
2. Bring the power leads in through the left entry on the bottom of the enclosure.
3. If necessary at remote locations, connect the GC chassis ground wire to an external
copper ground rod. See Section 3.3.3 regarding electrical and signal grounding.
3.5.3 Connect the sample and other gas lines
To install GC sample and gas lines, do the following:
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Installation and setup
1. Remove the plug from the 1/16-inch sample vent tubing marked “SV1” that is
located on the flow panel assembly. Depending on your GC’s configuration, there
may also be a second sample vent marked “SV2”. If so, remove its plug as well.
Sample vent (A) and measure vent (B) linesFigure 3-8:
Installation and setup
3
• If desired, connect the sample vent lines to an external, ambient pressure vent. If
the vent line is terminated in an area exposed to wind, protect the exposed vent
with a metal shield.
• Use ¼-inch or 3/8-inch tubing for vent lines longer than 10 feet.
At this stage in the installation the GC measure vent lines (marked “MV1” and
“MV2”) should remain plugged until the GC has been checked for leaks. For regular
operation, however, the MV lines must be unplugged.
Note
Do not discard the vent line plugs. They are useful at any time when leak-checking the GC and
its sample or gas line connections.
2. Connect the carrier gas to the GC. The carrier gas inlet is labeled “Carrier In” and is a
1/8-inch T-fitting.
WARNING!
Do not turn on sample gas until you have completely checked the carrier lines for leaks.
Failure to follow this warning may result in injury or death to personnel or cause
damage to the equipment.
• Use stainless steel tubing to conduct carrier gas.
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Installation and setup
• Use a dual-stage regulator with high-side capacity of 3000 psig and low-side
capacity of 150 psig.
• See Appendix B for a description of a dual-cylinder carrier gas manifold (P/N
3-5000-050) with these features: carrier gas is fed from two bottles; when one
bottle is nearly empty (100 psig), the other bottle becomes the primary supply;
and each bottle can be disconnected for refilling without interrupting GC
operation.
3. Connect calibration standard gas to the GC.
When installing the calibration standard gas line, ensure that the correct tubing
connection is made.
• Use 1/8-inch stainless steel tubing to connect calibration standard gas unless the
application requires treated tubing.
• Use a dual-stage regulator with low-side capacity of up to 30 psig.
Sample stream inlets (A) and calibration gas inlet (B)Figure 3-9:
44
4. Connect sample gas stream(s) to the GC.
• Use 1/8-inch stainless steel tubing, as appropriate, to connect calibration
standard gas.
• Unless stated otherwise in the product documentation, ensure that the pressure
of the calibration and sample line is regulated at 20 psig.
5. After all lines have been installed, proceed with leak-checking the carrier and sample
lines. See Section 3.6.
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Installation and setup
3.5.4 Maximum effective distance by communication protocol type
The table below lists the maximum distance at which the indicated protocol can transmit
data without losing effectiveness. If longer runs are required, the use of a repeater or other
type of extender will be necessary to maintain the protocol's efficiency.
Communication protocol Maximum Distance
RS-232 50ft (15.24m)
RS-422/RS-485 4000ft (1219.2m)
Ethernet (Cat5) 300ft (91.44m)
3.5.5 RS-485 serial port terminals
To ensure correct communication with all hosts, place a 120-ohm terminating resistor
across the GC serial port terminals on the RS-485 link. On a multi-dropped link, install the
terminating resistor on the last controller link only.
Installation and setup
3
3.5.6 Installing and connecting to an analog modem card
The 700XA has two slots—I/O Slot A and I/O Slot B—in the card cage for installing an analog
modem.
Note
MON2020 only recognizes Microsoft Windows-compatible modems that have all relevant drivers
installed correctly.
Note
Analog modems will only work with PSTN phone lines. Analog modems will not work with VOIP
networks.
The following four LEDs are provided on the modem for troubleshooting:
• RI (Ring Indicator) - This LED flashes when it senses a “ring”. This LED should only
flash once per connection because the modem automatically answers on the first
ring.
• CD (Carrier Detect) - This LED glows green while connected to MON2020.
• RX (Receive) - This LED flashes while the GC receives data from MON2020.
• TX (Transmit) - This LED flashes while the GC sends data to MON2020.
Installing the analog modem
To install an analog modem, do the following:
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Installation and setup
1. Start MON2020 and connect to the GC.
2. Select I/O Cards... from the Tools menu. The I/O Cards window displays.
3. Change the Card Type for the appropriate I/O slot to Communication Module -
Modem.
4. Click Save. MON2020 displays the following message:
The GC must be rebooted for the ROC Card changes to take effect
5. Click OK to dismiss the message.
6. Click OK to close the I/O Cards window.
7. Disconnect from the GC.
8. Turn off the GC.
9. Insert the analog modem card into the appropriate I/O slot in the GC’s card cage.
Make certain that the I/O slot matches that from Step 3.
10. Tighten the card’s screws to secure the modem in the slot.
11. Insert a telephone cable into the modem card’s RJ-11 socket.
12. Start the GC.
13. Return to MON2020 and connect to the GC via its Ethernet connection.
14. Select Communication... from the Application menu. The Communication window
displays. The appropriate I/O slot should be listed in the first column (Label).
15. Set the Baud Rate for the analog modem card to 57600.
16. Make note of the I/O slot’s Modbus Id.
17. Click Save.
18. Click OK to close the Communication window.
19. Disconnect from the GC.
3.5.7 Connecting to the GC via the analog modem
To connect to a GC via its analog modem, do the following:
1. Start MON2020 and select GC Directory... from the File menu. The GC Directory
window displays.
2. Select Add from the GC Directory window’s File menu. A row is added to the bottom
of the directory table.
3. Replace “GC Name” with a more appropriate identifier for the GC to which you will
be connecting.
Note
You can also enter more information about the GC in the Short Desc field.
4. Select the Modem check box.
5. Click the Modem... button. The Modem Connection Properties for DialUp window
displays.
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Installation and setup
6. Make sure that the Comm Address matches the Modbus Id from the Communication
window.
7. Select the appropriate modem from the Modem drop-down list. The Edit Telephone
Number dialog box displays.
8. Enter the modem’s telephone number and click OK. The Modem Properties window
displays.
9. Click OK to close the Modem Properties window.
10. Click the GC Directory window’s Save button.
11. Click the GC Directory window’s OK button to close the window.
12. Select Connect... from the Chromatograph menu. The Connect to GC window
displays.
13. Click the Modem button for the appropriate GC. The Login dialog box displays.
14. Enter the appropriate user name and password and click OK. MON2020 will connect
to the GC via the modem connection.
3.5.8 Connecting directly to a PC using the GC’s Ethernet port
Installation and setup
3
The GC’s DHCP server feature and its Ethernet port on the backplane at J22 allow you to
connect directly to the GC. This is a useful feature for GCs that are not connected to a local
area network; all that is needed is a PC—typically a notebook computer—and a CAT5
Ethernet cable.
Note
The PC must have an Ethernet network interface card (NIC) that supports the automatic mediumdependent interface crossover (Auto-MDIX) technology and either an Ethernet cable of at least CAT5
or an Ethernet Crossover Cable of at least CAT5.
Note
The GC can be connected (or remain connected) to the local network on TB11 on the backplane
while the DHCP feature is being used.
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Installation and setup
Ethernet ports on the backplaneFigure 3-10:
1. Plug one end of the Ethernet cable into the PC’s Ethernet port and the other end into
the GC’s RJ45 socket on J22 on the backplane.
2. Locate the set of switches at SW1, directly beneath the Ethernet port on the back
plane. Flip the switch that is labelled “1” to ON. This starts the GC’s DHCP server
feature. The server typically takes approximately 20 seconds to initialize and start
up.
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Installation and setup
SW1 switches on the back planeFigure 3-11:
Installation and setup
3
Note
Make sure the SW1 switch is set to off (1) before connecting the GC to your local network;
else, the GC will disrupt the local network's functioning.
3. Wait for 20 seconds and then do the following to ensure that the server has
provided an IP address to the PC:
a. From the PC, go to Start → Control Panel → Network Connections.
b. The Network Connections window lists all Dial-up and LAN / High-Speed Internet
connections installed on the PC. In the list of LAN / High Speed Internet
connections, find the icon that corresponds to the PC-to-GC connection and
check the status that displays beneath the “Local Area Connection”. It should
show the status as “Connected”. The PC is now capable of connecting to the GC.
See Using MON2020 to connect to the GC.
1. If the status is “Disconnected”, it may be that the PC is not configured to accept IP
addresses; therefore, do the following:
4. Right-click on the icon and select Properties. The Local Area Connection Properties
window displays.
5. Scroll to the bottom of the Connection list box and select Internet Protocol (TCP/
IP).
6. Click Properties. The Internet Protocol (TCP/IP) Properties window displays.
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Installation and setup
7. To configure the PC to accept IP addresses issued from the GC, select the Obtain an
IP address automatically and Obtain DNS server address automatically check
boxes.
8. Click OK to save the changes and to close the Internet Protocol (TCP/IP) Properties
window.
9. Click OK to close the Local Area Connection Properties window.
10. Return to the Network Connections window and confirm that the appropriate icon’s
status reads “Connected”. If the icon still reads “Disconnected” refer to
Section 3.5.9.
Note
If you power cycle the GC, then you will lose connectivity. After the GC initializes completely,
refer to Section 3.5.9 to learn how to “repair” the connection.
Using MON2020 to connect to the GC
To connect to the GC, do the following:
1. Start MON2020. After starting, the Connect to GC window displays.
2. Locate Direct-DHCP under the GC Name column. This GC directory is created
automatically when MON2020 is installed. It can be renamed but the IP address that
it references—192.168.135.100— should not be changed.
3. Click the associated Ethernet button. MON2020 prompts you to enter a user name
and password, after which you will be connected to the GC.
3.5.9 Troubleshooting DHCP connectivity issues
Use the following tips to troubleshoot server connectivity issues:
1. Ensure that the GC is up and running. If equipped with an front panel, check the
“CPU” LED on the front panel; a green light means that the GC is operational. If
equipped with an LOI, ensure that the LOI is communicating with the GC.
2. Check that the SW1 switch is ON.
3. Check the following connections:
a. If you are using a Ethernet straight cable, ensure that you the PC has an Ethernet
network interface card with auto-MDIX.
b. If your Ethernet network interface card does not support auto-MDIX, ensure that
you are using an Ethernet crossover patch cable.
c. Check to see if the CPU board’s link lights are on. The three lights are located on
the front bottom edge of the card. If link lights are off, then check your
connections.
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Installation and setup
CPU board link lightsFigure 3-12:
Installation and setup
3
4. Do the following to ensure that your network adapter is enabled:
a. Go to Start → Control Panel → Network Connections.
b. Check the status of the Local Area Connection icon. If the status appears as
Disabled, right-click on the icon and select Enable from the context menu.
5. Do the following to try to repair the network connection:
a. Go to Start → Control Panel → Network Connections.
b. Right-click on the Local Area Connection icon and select Repair from the context
menu.
3.5.10 Connecting directly to a PC using the GC’s serial port
The GC’s serial port at J23 on the back plane allows a PC with the same type of port to
connect directly to the GC. This is a useful feature for a GC that is located in an area
without internet access; all that is needed is a PC running Windows XP Service Pack 3,
Windows Vista, or Windows 7—typically a notebook computer—and a straight through
serial cable.
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Installation and setup
J23 serial port on the backplane (A)Figure 3-13:
To set up the PC for the direct connection, do the following:
1. Do the following to install the Daniel Direct Connect modem driver onto the PC:
a. Navigate to Start → Control Panel and double-click the Phones and Modem
Options icon. The Phones and Modem Options dialog displays.
b. Select the Modem tab and click Add…. The Add Hardware Wizard displays.
c. Select the Don’t detect my modem; I will select it from a list check box and
then click Next.
d. Click Have Disk. The Install from Disk dialog appears.
e. Click Browse and the Browse dialog displays.
f. Navigate to the MON2020 install directory (typically C:\Program Files\Emerson
Process Management\MON2020) and select Daniel Direct Connection.inf.
g. Click Open. You will be returned to the Install from Disk dialog.
h. Click OK. You will be returned to the Add Hardware Wizard.
i. Click Next.
j. Select an available serial port and click Next. The Hardware Installation dialog
displays.
k. Click Continue Anyway. After the modem driver is installed, you will be returned
to the Add Hardware Wizard.
l. Click Finish. You will be returned to the Phones and Modems dialog. The Daniel
Direct Connect modem should be listed in the Modem column.
2. Start MON2020 and do the following to create a GC connection for the Daniel
Direct Connection modem:
52
a. Select GC Directory from the File menu. The GC Directory window displays.
b. Select Add from the GC Directory window’s File menu. A New GC row will be
added to the bottom of the table.
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Installation and setup
c. Select the New GC text and type in a new name for the GC connection.
Note
You can enter optional but helpful information about the connection in the Short Desc
column.
d. Select the new GC’s Direct check box.
e. Click the Direct button located at the bottom of the GC Directory window. The
Direct Connection Properties window displays.
f. Select Daniel Direct Connection (COMn) from the Port drop-down window.
Note
The letter n stands for the COM number.
g. Select 57600 from the Baud Rate drop-down window.
h. Click OK to save the settings. You will be returned to the GC Directory window.
i. Click OK to save the new GC connection and to close the GC Directory window.
3. Connect one end of the direct connect cable to the GC’s serial port at J23 on the
back plane.
4. Connect the other end of the direct connect cable to the PC’s corresponding serial
port.
5. Select Connect… from the Chromatograph menu. The Connect to GC window
displays.
6. Click Direct to connect to the GC using the serial cable connection.
3.5.11 Connecting directly to a PC using the GC’s wired
Installation and setup
3
Ethernet terminal
The 700XA has a wired Ethernet terminal at TB11 on the backplane that you can connect
to with a static IP address. All that is needed is a PC—typically a notebook computer—and a
2-Twisted Pair CAT 5 Ethernet cable with one of its plugs cut off to expose the wires.
Crimped CAT 5 cableFigure 3-14:
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Installation and setup
Note
The GC can be connected (or remain connected) to the local network on TB11 on the back plane
while the DHCP feature is being used.
Wired Ethernet terminal block on the backplaneFigure 3-15:
Use the following schematics as a guide to wiring the GC via its Phoenix connector at TB11.
Figure 3-16 shows the traditional wiring scheme; Figure 3-17 shows how to wire a CAT5e
cable if you cut off its RJ-45 plug.
Field wiring to TB11Figure 3-16:
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Installation and setup
CAT5e wiring to TB11Figure 3-17:
Installation and setup
3
Once you have wired the cable to the Ethernet terminal, plug the other end into a PC or a
wall jack. See Section 3.5.12 to continue configuring the GC.
3.5.12 Assigning a static IP address to the GC
To configure the GC with a static IP address, do the following:
1. Start MON2020 and log on to GC using a direct Ethernet connection. For more
information, refer to Section 3.5.8.
2. Select Ethernet ports... from the Applications menu. The Ethernet Ports window
displays.
3. Depending upon the Ethernet port to which you want to assign a static IP address,
do the following:
a. The Ethernet port at TB11: Enter the appropriate values in the Ethernet 2 IP
Address, the Ethernet 2 Subnet, and the Default Gateway fields.
b. The RJ-45 Ethernet port at J22: Enter the appropriate values in the Ethernet 1 IP
Address, the Ethernet 1 Subnet, and the Default Gateway fields.
Note
IP, Subnet, and Gateway addresses can usually be obtained from a member of your IT
staff.
4. Click OK.
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Installation and setup
5. Log off the GC.
6. Access the backplane, which is located in the GC’s lower enclosure.
Port locations on the backplaneFigure 3-18:
56
7. If you are setting up a static IP address for the Ethernet port at J22, and you also
intend to connect to your company’s local area network, do the following:
a. Locate the set of dip switches, labeled 1 and 2, at SW1 on the backplane. SW1 is
located directly beneath the Ethernet port at J22.
b. Move dip switch 1 to its left position. This disables the DHCP server.
1. To connect to the GC, do the following:
8. Start MON2020 and select GC Directory… from the File menu. The GC Directory
window displays.
9. Select Add from the GC Directory window’s File menu. A New GC profile will be
added to the end of table.
Note
You can also rename the GC’s profile as well as add a short description.
Page 65
10. Select the new profile and click Ethernet... Enter the GC’s static IP address in the IP
address field.
11. Click OK. The Ethernet Connection Properties for New GC window closes.
12. Click Save on the GC Directory window.
13. Click OK to close the GC Directory window.
14.
Select Connect... from the Chromatograph menu or click the icon. The
Connect to GC window displays.
15. The newly created GC profile should be listed in the table. Locate it and click the
Ethernet button that is associated with it. The Login window displays.
16. Enter a User Name and User Pin and click OK.
3.5.13 Discrete digital I/O wiring
The GC’s back plane has five discrete outputs and five discrete inputs. Refer to the
MON2020 user manual to learn how to configure the digital outputs.
Discrete digital inputs
Installation and setup
Installation and setup
3
To connect digital signal input lines to the GC, do the following:
1. Access the back plane.
The discrete inputs are located on TB7.
TB7 on the backplaneFigure 3-19:
Note
The discrete digital input terminals on the backplane are selp-powered. Devices connected to
the digital input will be powered by the GC's dedicated isolated 24V power supply.
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Installation and setup
Note
The discrete digital input terminals are optically isolated from the GC's other circuitry.
2. Route digital I/O lines appropriately, especially in the case of the explosion-proof
enclosure.
There are connections for five digital inputs and five digital output lines, as indicated
in the following table:
Discrete Digital InputsTable 3-1:
TB7 Function
Pin 1 F_DIG_IN1
Pin 2 DIG_GND
Pin 3 F_DIG_IN2
Pin 4 DIG_GND
Pin 5 F_DIG_IN3
Pin 6 DIG_GND
Pin 7 F_DIG_IN4
Pin 8 DIG_GND
Pin 9 F_DIG_IN5
Pin 10 DIG_GND
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Typical field wiring of a ROC800 DI module
Typical wiringFigure 3-20:
Installation and setup
Installation and setup
3
Terminal Label Definition
1 1 CH 1 Positive
2 2 CH 2 Positive
3 3 CH 3 Positive
4 4 CH 4 Positive
5 5 CH 5 Positive
6 6 CH 6 Positive
7 7 CH 7 Positive
8 8 CH 8 Positive
9 COM Common
10 COM Common
To connect the ROC800 DI module to a field device, do the following:
1. Expose the end of the wire to a maximum length of ¼ inch (6.3mm).
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Installation and setup
Note
Twisted-pair cables are recommended for I/O signal wiring. The module’s terminal blocks
accept wire sizes between 12 and 22 AWG. A minimum of bare wire should be exposed to
prevent short circuits. Allow some slack when making connections to prevent strain.
2. Insert the exposed end into the clamp beneath the termination screw.
3. Tighten the screw.
Discrete digital outputs
The discrete outputs are located on TB3, which is a 15-pin Phoenix connector, and have
five Form-C relays on the back plane. All contact outputs have a rating of 1A @30 VDC.
TB3 on the backplaneFigure 3-21:
60
Table 3-2 lists the discrete digital output function for each pin on the TB3 connector.
Discrete Digital OutputsTable 3-2:
TB3 Function
Pin 1 DIG_OUT NC1
Pin 2 DIG_OUT ARM1
Pin 3 DIG_OUT NO1
Pin 4 DIG_OUT NC2
Pin 5 DIG_OUT ARM2
Pin 6 DIG_OUT NO2
Pin 7 DIG_OUT NC3
Pin 8 DIG_OUT ARM3
Pin 9 DIG_OUT NO3
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Installation and setup
Discrete Digital Outputs (continued)Table 3-2:
TB3 Function
Pin 10 DIG_OUT NC4
Pin 11 DIG_OUT ARM4
Pin 12 DIG_OUT NO4
Pin 13 DIG_OUT NC5
Pin 14 DIG_OUT ARM5
Pin 15 DIG_OUT NO5
Note
Form-C relays are single-pole double-throw (SPDT) relays that have three positions: normally closed
(NC); an intermediate position, also called the “make-before-break” position (ARM); and normally
open (NO).
Optional discrete digital inputs
Installation and setup
3
When plugged into one of the optional card slots on the card cage, the ROC800 DI card
provides eight additional discrete digital inputs. The discrete digital inputs can monitor the
status of relays, open-collector or open-drain type solid-state switches, and other twostate devices. For more information, see “ROC800-Series Discrete Input Module” at
Emerson Process Management’s ROC 800-Series web site.
Optional card slotsFigure 3-22:
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Installation and setup
Typical field wiring of a ROC800 DO module
Typical wiringFigure 3-23:
Terminal Label Definition
1 1+ Positive discrete output
2 COM Discrete output return
3 2+ Positive discrete output
4 COM Discrete output return
5 3+ Positive discrete output
6 COM Discrete output return
7 4+ Positive discrete output
8 COM Discrete output return
9 5+ Positive discrete output
10 COM Discrete output return
To connect the ROC800 DO module to a field device, do the following:
1. Expose the end of the wire to a maximum length of ¼ inch (6.3mm).
Note
Twisted-pair cables are recommended for I/O signal wiring. The module’s terminal blocks
accept wire sizes between 12 and 22 AWG. A minimum of bare wire should be exposed to
prevent short circuits. Allow some slack when making connections to prevent strain.
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2. Insert the exposed end into the clamp beneath the termination screw.
3. Tighten the screw.
3.5.14 Analog input wiring
Installation and setup
All 700XAs have at least two analog inputs. An additional four analog inputs are available
with a ROC800 AI-16 card that can be installed into one of the optional slots in the card
cage.
Analog inputs on the blackplane
There are two analog input connections on the backplane at TB10.
TB10 on the black planeFigure 3-24:
Installation and setup
3
Analog InputsTable 3-3:
TB10 Function
Pin 1 +AI_1
Pin 2 -AI_1
Pin 3 +AI_2
Pin 4 -AI_2
Factory settings for analog input switches
Figure 3-25 shows the factory settings for the analog input switches that are located on the
Base I/O board. These analog inputs are set to accept a current (4-20 mA) source.
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Installation and setup
Factory settings for analog input switchesFigure 3-25:
Note
To set an analog input to accept a voltage (0-10 VDC) source, flip the appropriate switch in the
opposite direction from that shown in Figure 3-25.
Selecting the input type for an analog input
An analog input can be set to either voltage (0-10V) or current (4-20 mA) by flipping the
appropriate switches on the Base I/O board.
1. Turn off the GC.
2. Locate and remove the Base I/O board, which is in the card cage in the GC’s lower
enclosure.
3. To set analog input #1 to current, locate SW1 on the Base I/O board and push the
switches up, toward the card ejector; to set the analog input to voltage, push the
switches down, away from the card ejector.
4. To set analog input #2 to current, locate SW2 on the Base I/O board and push the
switches up, toward the card ejector; to set the analog input to voltage, push the
switches down, away from the card ejector.
5. Replace the Base I/O board in the card cage.
6. Start up the GC.
7. Start MON2020 and connect to the GC.
8. Select Analog Inputs from the Hardware menu. The Analog Inputs window displays.
9. To set the analog input to current, select mA from the mA/Volts drop-down list for
the appropriate analog input; to set the analog input to voltage, select Volts from
the mA/Volts drop-down list for the appropriate analog input.
10. Click Save to save the changes and keep the window open, or click OK to save the
changes and close the window.
Typical wiring for line-powered transmitters
64
The following drawing shows the most common wiring plan for supplying power to two
4-20 mA transmitters, such as pressure sensor transmitters.
Page 73
Typical wiring for line-powered transmittersFigure 3-26:
Optional analog inputs
Installation and setup
Installation and setup
3
When plugged into one of the optional card slots on the card cage, the ROC800 AI-16 card
provides four additional analog inputs. The AI channels are scalable, but are typically used
to measure either a 4-20 mA analog signal or a 1-5 V dc signal. If required, the low end of
the AI module’s analog signal can be calibrated to zero. For more information, see “Analog
Input Modules (ROC800-Series)” at Emerson Process Management’s ROC 800-Series web
site.
Optional card slotsFigure 3-27:
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Installation and setup
Typical field wiring of a ROC800 AI-16 module
Typical wiringFigure 3-28:
To connect the ROC800 AI-16 module to a device, do the following:
CAUTION!
Failure to exercise proper electrostatic discharge precautions—such as wearing a grounded
wrist strap—may reset the processor or damage electronic components, resulting in
interrupted operations. Ground loops may be induced by tying commons from various
modules together.
1. Expose the end of the wire to a maximum length of ¼ inch (6.3mm).
Note
Twisted-pair cables are recommended for I/O signal wiring. The module’s terminal blocks
accept wire sizes between 12 and 22 AWG. A minimum of bare wire should be exposed to
prevent short circuits. Allow some slack when making connections to prevent strain.
2. Insert the exposed end into the clamp beneath the termination screw.
3. Tighten the screw.
There are two dip switches on the terminal block side of the module that can be
used to set a 250 Ω resistor in or out of circuit for each analog input.
To put an analog input’s resistor in circuit, flip the appropriate dip switch to “I”; to
put an analog input’s resistor out of circuit, flip the appropriate dip switch to “V”.
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Installation and setup
Calibrating a ROC800 AI-16 module
To calibrate the ROC800 AI-16 module you must have a PC with the ROCLINK 800
Configuration program installed and open.
1. Select the Configure → I/O → RTD Points → Calibration tab.
2. Select an Analog Input.
3. Click Update to request one value update from the input.
4. Click Freeze to stop the values of the input from being updated during calibration.
Note
If you are calibrating a temperature input, disconnect the RTD sensor and connect a decade
box or comparable equipment to the RTD terminals of the ROC card.
5. Click Calibrate.
6. Enter a value for Set Zero after stabilization.
7. Enter a value for Set Span after stabilization.
8. Enter values for up to three Midpoints one at a time or click Done if you are not
configuring Midpoints.
9. Click OK to close the main calibration window and unfreeze the associated inputs.
To calibrate the inputs for another analog input, return to Step 1.
Installation and setup
3
3.5.15 Analog output wiring
All 700XAs have at least six analog outputs. An additional four analog inputs are available
with a ROC800 AO card that can be installed into one of the optional slots in the card cage.
Analog outputs on the backplane
There are six analog output connections on the backplane at TB4.
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Installation and setup
TB4 on the black planeFigure 3-29:
Analog OutputsTable 3-4:
TB4 Function
Pin 1 + Loop1
Pin 2 Loop_RTN1
Pin 3 + Loop 2
Pin 4 Loop_RTN2
Pin 5 + Loop 3
Pin 6 Loop_RTN3
Pin 7 + Loop 4
Pin 8 Loop_RTN4
Pin 9 + Loop 5
Pin 10 Loop_RTN5
Pin 11 + Loop 6
Pin 12 Loop_RTN6
Factory settings for analog output switches
This drawing shows how to wire up to six devices to the analog outputs that are located on
the back plane. It also shows how to wire up to two analog inputs.
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Installation and setup
Wiring for six analog outputsFigure 3-30:
Installation and setup
3
Figure 3-31 shows the factory settings for the analog output switches that are located on
the Base I/O board.
Factory settings for analog output switchesFigure 3-31:
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Installation and setup
Wiring for customer-powered analog outputsFigure 3-32:
Wiring and switch settings for customer-powered analog outputs
It is possible to furnish power to each analog output while maintaining isolation between
channels.
Consult the following diagrams before wiring a customer-powered device:
1. This drawing shows the wiring that is necessary to provide power to each analog
output while maintaining isolation between channels.
70
2. This drawing shows the settings for the analog output switches, located on the Base
I/O board, that are necessary to provide power to each analog output while
maintaining isolation between channels.
Page 79
Installation and setup
Settings for analog output switchesFigure 3-33:
Optional analog outputs
When plugged into one of the optional card slots on the card cage, the ROC800 AO card
provides four additional analog outputs. Each channel provides a 4 to 20 mA current signal
for controlling analog current loop devices. For more information, see “ROC800-Series
Analog Output Module” at Emerson Process Management’s ROC 800-Series web site.
Typical field wiring of a ROC800 AO module
Installation and setup
3
Typical wiringFigure 3-34:
Terminal Label Definition
1 1+ Positive analog output
2 COM Analog output return
3 2+ Positive analog output
4 COM Analog output return
5 3+ Positive analog output
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Installation and setup
Terminal Label Definition
6 COM Analog output return
7 4+ Positive analog output
8 COM Analog output return
9 N/A Not used
10 N/a Not used
To connect the ROC800 AO module to a field device, do the following:
1. Expose the end of the wire to a maximum length of ¼ inch (6.3mm).
Note
Twisted-pair cables are recommended for I/O signal wiring. The module’s terminal blocks
accept wire sizes between 12 and 22 AWG. A minimum of bare wire should be exposed to
prevent short circuits. Allow some slack when making connections to prevent strain.
2. Insert the exposed end into the clamp beneath the termination screw.
3. Tighten the screw.
3.6 Leak checking and purging for first calibration
Verify that all electrical connections are correct and safe, and then turn the unit on.
3.6.1 Checking the GC for leaks
To perform a leak check, do the following:
1. Plug all vents.
2. Make sure the setting of the carrier gas cylinder gauge is 115 psig and/or the valve
actuation pressure is between 110 and 120 psig.
3. Check all fittings at the pressure gauge flow panel and at the carrier gas cylinder
gauge with a leak detector. Correct any leaks detected.
4. Turn the carrier gas cylinder shut-off valve clockwise to close. Observe the carrier
gas pressure for ten minutes to check for a drop in carrier pressure. The drop should
be less than 200 psig on the high side of the gauge. If the carrier gas is lost at a faster
rate, check for leaks between the carrier gas bottle and the analyzer.
5. Use the LOI or MON2020 to actuate the valves on and off 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 cylinder
valve to restore pressure if necessary.
6. If the pressure does not hold relatively constant, check all valve fittings for tightness.
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7. Repeat Step 5 again. If leaks persist, check the valve ports with a commercial gas leak
detector. Do not use a liquid leak detector such as Snoop® on the valves or
components in the oven.
3.6.2 Purging carrier gas lines
Installation and setup
Purging carrier and calibration gas lines requires power and a PC connected to the GC.
Note
Tubing should be clean and dry internally. During installation, the tubing should have been blown
free of internal moisture, dust, or other contaminants.
To purge the carrier gas lines, do the following:
1. Ensure that the measure vent line plugs have been removed, and the vent lines are
open.
2. Ensure that the carrier gas bottle valve is open.
3. Set the “GC side” of the carrier gas to 120 psig.
4. Turn on the GC and the PC.
5. Start MON2020 and connect to the GC.
Note
Consult the MON2020 Software for Gas Chromatograph manual for information about
connecting to a GC.
6. Select Hardware → Heaters. The Heaters window displays. The temperature values for
the heaters should indicate that the unit is warming up.
Installation and setup
3
The Heaters windowFigure 3-35:
7. Allow the GC system temperature to stabilize and the carrier gas lines to become
fully purged with carrier gas, which usually takes about an hour.
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Installation and setup
8. Select Control → Auto Sequence.
For more information about this function, refer to the MON2020 Software for Gas
Chromatographs manual.
Note
A purging period of 4 to 8 hours (or overnight) is recommended, during which no changes
should be made to the settings described in Step 1 through Step 7.
3.6.3 Purging calibration gas lines
To purge the calibration gas lines, do the following:
1. Ensure that the carrier gas lines have been fully purged and that the sample vent
plugs have been removed.
2. Close the calibration gas bottle valve.
3. Fully open the block valve associated with the calibration gas feed. The block valve is
located on the lower right-hand corner of the front panel. Refer to the MON2020
Software for Gas Chromatographs manual for instructions on selecting streams.
4. Open the calibration gas bottle valve.
5. Increase the outlet pressure to 40 psig, plus or minus five percent, at the calibration
gas bottle regulator.
6. Close the calibration gas bottle valve.
7. Let both gauges on the calibration gas bottle valve bleed down to 0 psig.
8. Repeat Step 4 through Step 7, five times.
9. Open the calibration gas bottle valve.
3.7 System startup
To perform system start-up, do the following:
1. For system startup, run an analysis of the calibration gas.
a. If equipped with a stream switching board or LOI, ensure that the calibration
stream is set to AUTO.
Unless stated otherwise in the product documentation, ensure that the pressure
of the calibration and sample line is regulated at 3 to 30 psig (15 psig is
recommended).
b. Use MON2020 to run a single stream analysis on the calibration stream. Once
proper operation of the GC is verified, halt the analysis by selecting Control → Halt.
Refer to the MON2020 Software for Gas Chromatographs manual for more
information.
2. Select Control → Auto Sequence to start auto sequencing of the line gas stream(s).
Refer to the MON2020 Software for Gas Chromatographs manual for more
information. The GC will begin the Auto Sequence analysis.
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4 Operation and maintenance
4.1 Warning and precautions
WARNING!
Operation and maintenance
Observe all precautionary signs posted on the 700XA. Failure to do so can result in injury or
death to personnel or cause damage to the equipment.
CAUTION!
Turn off GC before removing a card from the card cage assembly. Failure to do so can result in
damage to the card.
4.2 Start a two-point calibration
The 2-Point Calibration process calculates an exponential power fit that the GC uses to
accurately analyze a sample stream with a Flame Photometric Detector (FPD). The 2-Point
Calibration process requires two calibration gases that will be used to generate the data for
the exponential power fit calculation. While both calibration gases should have the same
components, one of the calibrations gases, called the low calibration gas (LCG) should have
a lower concentration of the components than the other calibration gas, which is called
the high calibration gas (HCG). The GC can then compute the coefficients for the 2 Pt
exponential power fit by doing a single-level calibration on these individual LC and HC
streams.
1. Start MON2020 and press F6 to open the Component Data screen.
2. Change the Calib Type for the target component to 2 pt Calib.
3. For the target component, select the CDT that is associated with the LCG from the 2
Pt Calib Low CDT drop-down list.
4. For the target component, select the CDT that is associated with the HCG from the 2
Pt Calib High CDT drop-down list.
5. Run a Single Stream analysis on the stream associated with the LCG until the
readings stabilize.
6. Run a Forced Calibration on the stream associated with the LCG.
7. Run a Normal Calibration on the stream associated with the LCG.
8. Run a Single Stream analysis on the stream associated with the HCG until the
readings stabilize.
9. Run a Forced Calibration on the stream associated with the HCG.
10. Run a Normal Calibration on the stream associated with the HCG.
Operation and maintenance
4
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Operation and maintenance
The GC is ready to analyze the sample or validation stream using the 2 Pt Exp and
the Resp Factor that were calculated during the LCG and HCG runs.
4.3 Troubleshooting and repair concept
The most efficient method for maintaining and repairing the 700XA is a componentreplacement concept that allows you to return the system to operation as quickly as
possible. Sources of trouble, such as printed-circuit assemblies, valves, etc., are identified
during troubleshooting test procedures and are replaced at the lowest level practical with
units in known working order. The defective components are then either repaired in the
field or returned to Measurement Services for repair or replacement.
4.4 Routine maintenance
The 700XA will perform accurately for long periods with very little attention (except for
maintaining the carrier gas cylinders). A bimonthly record of certain parameters will assist
greatly in assuring that your 700XA is operating to specifications. The maintenance
checklist should be filled out bimonthly, dated, and kept on file for access by maintenance
technicians as necessary. This gives you a historical record of the operation of your 700XA,
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 record of the 700XA. The
chromatogram and reports can also be compared to the chromatograms and reports run
during the troubleshooting process.
4.4.1 Maintenance checklist
Print the sample maintenance checklist on the following page as necessary for your files. If
you have a problem, please complete the checklist first and have the results available, as
well as the sales order number, when calling your Emerson Process Management
representative for technical assistance. The sales order number can be found on the
nameplate located on the right side wall of the GC. The chromatograms and reports
archived when your GC left the factory are filed by this number.
Note
To find the default measurements for the parameters on the checklist, use MON2020 to view the
GC’s Parameter List.
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Operation and maintenance
Operation and maintenance
4
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Operation and maintenance
4.4.2 Routine maintenance procedures
• To give yourself a basis for comparison in the future, complete the maintenance
checklist at least two times each month. Place the sales order number, date, and
time on the form and file it.
• Save a chromatogram of the operating GC on the PC with MON2020. Print
configuration, calibration, and raw data reports and file them with MON2020.
• Check the printer paper (if used) to ensure that a sufficient supply of paper remains.
Check carrier and calibration gas supplies.
Service programs
Measurement Services offers maintenance service programs that are tailored to fit specific
requirements. Contracts for service and repair can be arranged by contacting
Measurement Services at the address or telephone number on the Customer Repair Report
at the back of this manual.
4.4.3 Precautions for handling PC assemblies
Printed circuit assemblies contain CMOS integrated circuits, which can be damaged if the
assemblies are not properly handled. The following precautions must be observed when
working with the assemblies:
• Do not install or remove the 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 grounded surface to prevent static discharge when
installing or removing printed circuit assemblies.
Note
CPU boards are switched off before shipping to preserve the board's battery. Before installing into
the GC, be sure to switch the CPU board on.
4.4.4 General troubleshooting
This section contains general troubleshooting information for the 700XA. The information
is arranged as appropriate either by major subsystems or by major functions of the
instrument. Refer to Hardware alarms for frequent causes of hardware alarms.
78
Note
Correct ALL alarms before re-calibration.
Page 87
Operation and maintenance
Hardware alarms
Use the following table to identify the alarm and possible cause and solution for the
problem.
Alarm Name Possible Causes/Solution
LTLOI Failure No switch panel detected or connected.
Recommended actions:
1. Power the GC down completely.
2. Check that the board is seated in the correct slot of the backplane board.
3. Power up the GC.
4. If message appears again, replace Switch Panel Board.
Maintenance Mode A technician has put the GC into maintenance mode for servic-
ing.
To disable maintenance mode, unclick the Maintenance Mode
check box in the System dialog.
Power Failure The GC has experienced a re-start since alarms were last cleared,
caused by power failure. The GC automatically starts in warm
start mode.
During warm start mode, the GC does the following:
1. Waits for the heaters to stabilize.
2. Purges the sample loop.
3. Actuates the valves for two cycles.
After completing these actions, the GC switches to auto-sequence mode.
User Calculation Failure One or more errors were detected while parsing a user-defined
calculations. This usually happens when a user-defined calculation attempts to use a system variable that does not exist.
Recommended action: Fix the calculation that is referring to the
undefined system variable.
FF Board Comm Failure Foundation Fieldbus board not detected.
Recommended actions:
1. Power the GC down completely.
2. Check that the Foundation Fieldbus module cable is properly
seated in the correct slot on the backplane board.
3. Check that the board is securely plugged into the Foundation
Fieldbus module.
4. Check that the Foundation Fieldbus module is receiving power.
5. Power up the GC.
6. If the alarm appears again, replace the Foundation Fieldbus
board.
Operation and maintenance
4
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Operation and maintenance
Alarm Name Possible Causes/Solution
Low Battery Voltage A low battery voltage has been detected on the CPU board. Re-
Preamp Board 1 Comm Failure Preamp board not detected.
Preamp Board 2 Comm Failure Preamp board not detected.
Heater Solenoid Board 1 Comm
Failure
Heater Solenoid Board 2 Comm
Failure
BaseIO Board Comm Failure Base I/O (Multifunction I/O) board not detected.
place the CPU board immediately to avoid losing GC configuration data.
Recommended actions:
1. Save the GC Configuration to a PC.
2. Save any Chromatograms and/or Results to a PC.
3. Power down the GC.
4. Replace the CPU Board.
5. Restore Configuration back to the GC.
Recommended actions:
1. Power the GC down completely.
2. Check that the board is properly seated in the correct slot
(SLOT 1) on the backplane.
3. Power up the GC.
4. If message appears again, replace the preamp board.
Recommended actions:
1. Power the GC down completely.
2. Check that the board is properly seated in the correct slot
(SLOT 3) on the backplane.
3. Power up the GC.
4. If message appears again, replace the preamp board.
Heater/Solenoid board not detected.
Recommended actions:
1. Power the GC down completely.
2. Check that the board is properly seated in the correct slot
(SLOT 2) on the backplane.
3. Power up the GC.
4. If message appears again, replace the heater/solenoid board.
Heater/Solenoid board not detected.
Recommended actions:
1. Power the GC down completely.
2. Check that the board is properly seated in the correct slot
(SLOT 4) on the backplane.
3. Power up the GC.
4. If message appears again, replace the heater/solenoid board.
Recommended actions:
1. Power the GC down completely.
2. Check that the board is properly seated in the correct slot
(SLOT 5) on the backplane.
3. Power up the GC.
4. If message appears again, replace the Base IO board.
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Operation and maintenance
Alarm Name Possible Causes/Solution
Stream Skipped One or more streams in the stream sequence cannot be analyzed
because their “Usage” option is set to “Unused”.
Recommended actions:
Use MON2020 to do one of the following:
Remove the unused stream(s) from the stream sequence.
Change the Usage option of the stream(s) in the Streams dialog
to something other than “Unused”.
GC Idle The GC has been placed in Idle mode and is not running an analy-
sis.
Warm Start Failed The GC failed to achieve desired operating condition after power
up. Unable to regulate heater zone temperature(s).
Recommended actions:
1. Check heater settings in MON2020 or the LOI.
2. Check that the carrier gas cylinder pressure is 10 psi (or
greater) above the mechanical regulator set point.
3. Confirm that carrier cylinder has flow to the GC.
4. Check for leaks in the carrier gas sample path.
5. Confirm that RTDs are not open.
6. If necessary, replace RTD(s), heater(s) and/or regulator(s).
Heater 1 Out Of Range
Heater 2 Out Of Range
Heater 3 Out Of Range
Heater 4 Out Of Range
Heater 5 Out Of Range
Heater 6 Out Of Range
Heater 7 Out Of Range
Heater 8 Out Of Range
Flame Out The FID flame will not light or has extinguished.
The GC failed to regulate heater zone temperatures for the indicated heater to within preset limits.
Recommended actions:
1. Check temperatures within the GC, using MON2020 or the
LOI. Be aware that the GC may generate this alarm during
start up or if the set point has been changed.
2. Check wiring, looking for splits or loose connections at the
termination board (for both the heaters and the RTDs).
3. If necessary, replace the defective heater and/or RTD.
Recommended actions:
1. Use the front switch panel or the LOI or MON2020 to ignite
the FID.
2. If unable to sustain the flame, confirm that both fuel and air
cylinders are connected and contain sufficient pressure.
3. Confirm that fuel and air set points are set to achieve factorydesired mixture.
4. Confirm that there is no blockage at the FID outlet - such as a
cap or ice.
5. Check that the wiring connections are secure for the FID,
both on the FID cap and at the termination board.
6. If necessary, replace the FID module.
Operation and maintenance
4
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Operation and maintenance
Alarm Name Possible Causes/Solution
Flame Over Temperature The FID flame temperature is above safe limits set at the factory
Detector 1 Scaling Factor Failure
Detector 2 Scaling Factor Failure
Detector 3 Scaling Factor Failure
Detector 4 Scaling Factor Failure
and the FID flame has been extinguished, the fuel supply valve
closed, and automatic analyses halted.
Recommended actions:
1. Confirm that both fuel and air cylinders are connected and
contain sufficient volume.
2. Confirm that fuel and air set points are set to achieve desired
mixture.
3. Use the front switch panel or the LOI or MON2020 to ignite
the FID.
The GC detected an excess scaling factor deviation for Detector
#1.
Recommended action: Replace the preamp board located in
SLOT 1 on the backplane.
The GC detected an excess scaling factor deviation for Detector
#2.
Recommended action: Replace the preamp board located in
SLOT 1 on the backplane.
The GC detected an excess scaling factor deviation for Detector
#3.
Recommended action: Replace the preamp board located in
SLOT 3 on the backplane.
The GC detected an excess scaling factor deviation for Detector
#4.
Recommended action: Replace the preamp board located in
SLOT 3 on the backplane.
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Operation and maintenance
Alarm Name Possible Causes/Solution
No sample flow 1
(Applies to the optional sample
flow switch.)
No sample flow 2 Refer to “No sample flow 1”.
Low Carrier Pressure 1 Input carrier pressure for detector 1 is below the preset limit.
Low Carrier Pressure 2 Input carrier pressure for detector 2 is below the preset limit.
Analog Input 1 High Signal
Analog Input 2 High Signal
Analog Input 3 High Signal
Analog Input 4 High Signal
Analog Input 5 High Signal
Analog Input 6 High Signal
Analog Input 7 High Signal
Analog Input 8 High Signal
Analog Input 9 High Signal
Analog Input 10 High Signal
There is no sample flow in the GC.
Recommended actions:
Check sample gas rotometer in the sample conditioning system
for flow and do one of the following:
If no gas flow or no rotometer is present, do the following:
1. Confirm that there is gas flow at the sample point location.
2. Check that the sample valves in the sample conditioning system are open.
3. Check that the bypass return vent path is free of obstruction.
4. Confirm that the sample line is connected from the sample
point to the GC’s sample conditioning system and is free of
obstructions.
5. Close the valve at the sample tap, remove pressure from the
line and check the filters at the probe or the sample conditioning system or both. If they are filled with liquids or particulates, replace the filtering elements.
If automatic stream selection valves are present, confirm that
they are operating properly.
If a slight sample gas flow is present at the rotometer in the sample conditioning system, drain or replace all filters.
If flow is observed in the rotometer, replace the sample flow
switch because it might have failed.
Recommended action: Check that the carrier cylinder pressure is
10 psi (or greater) above the mechanical regulator set point. If input carrier pressure is low, check the carrier cylinder pressure.
Replace carrier gas cylinder if required.
Recommended action: Check that the carrier cylinder pressure is
10 psi (or greater) above the mechanical regulator set point. If input carrier pressure is low, check the carrier cylinder pressure.
Replace carrier gas cylinder if required.
Measured value for the indicated analog input is greater than the
user-defined full scale range.
Operation and maintenance
4
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Operation and maintenance
Alarm Name Possible Causes/Solution
Analog Input 1 Low Signal
Analog Input 2 Low Signal
Analog Input 3 Low Signal
Analog Input 4 Low Signal
Analog Input 5 Low Signal
Analog Input 6 Low Signal
Analog Input 7 Low Signal
Analog Input 8 Low Signal
Analog Input 9 Low Signal
Analog Input 10 Low Signal
Analog Output 1 High Signal
Analog Output 2 High Signal
Analog Output 3 High Signal
Analog Output 4 High Signal
Analog Output 5 High Signal
Analog Output 6 High Signal
Analog Output 7 High Signal
Analog Output 8 High Signal
Analog Output 9 High Signal
Analog Output 10 High Signal
Analog Output 11 High Signal
Analog Output 12 High Signal
Analog Output 13 High Signal
Analog Output 14 High Signal
Analog Output 1 Low Signal
Analog Output 2 Low Signal
Analog Output 3 Low Signal
Analog Output 4 Low Signal
Analog Output 5 Low Signal
Analog Output 6 Low Signal
Analog Output 7 Low Signal
Analog Output 8 Low Signal
Analog Output 9 Low Signal
Analog Output 10 Low Signal
Analog Output 11 Low Signal
Analog Output 12 Low Signal
Analog Output 13 Low Signal
Analog Output 14 Low Signal
Measured value for the indicated analog input is lower than the
user-defined full scale range.
Measured value for the indicated analog output is greater than
the user-defined full scale range.
Measured value for the indicated analog output is lower than the
user-defined zero range.
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Alarm Name Possible Causes/Solution
Stream 1 Validation Failure
Stream 2 Validation Failure
Stream 3 Validation Failure
Stream 4 Validation Failure
Stream 5 Validation Failure
Stream 6 Validation Failure
Stream 7 Validation Failure
Stream 8 Validation Failure
Stream 9 Validation Failure
Stream 10 Validation Failure
Stream 11 Validation Failure
Stream 12 Validation Failure
Stream 13 Validation Failure
Stream 14 Validation Failure
Stream 15 Validation Failure
Stream 16 Validation Failure
Stream 17 Validation Failure
Stream 18 Validation Failure
Stream 19 Validation Failure
Stream 20 Validation Failure
Stream 1 RF Deviation
Stream 2 RF Deviation
Stream 3 RF Deviation
Stream 4 RF Deviation
Stream 5 RF Deviation
Stream 6 RF Deviation
Stream 7 RF Deviation
Stream 8 RF Deviation
Stream 9 RF Deviation
Stream 10 RF Deviation
Stream 11 RF Deviation
Stream 12 RF Deviation
Stream 13 RF Deviation
Stream 14 RF Deviation
Stream 15 RF Deviation
Stream 16 RF Deviation
Stream 17 RF Deviation
Stream 18 RF Deviation
Stream 19 RF Deviation
Stream 20 RF Deviation
The most recent validation sequence for the indicated stream
failed.
Recommended actions:
1. Check that the validation gas cylinder isolation valves are
open.
2. Check that the validation gas regulators are set properly.
3. If the validation gas regulator is below the set point, replace
the gas bottle with a full one.
4. If the gas used for validation is the same as the gas that is
used for calibration, ensure that the cylinder gas composition
value listed on the cylinder's tag or on the certificate of analysis received from the supplier matches the value displayed in
MON2020's Component Data table.
5. Re-run the validation sequence.
6. If still unsuccessful contact your Emerson Process Management representative.
The most recent calibration sequence failed.
Recommended actions:
1. Check that the calibration gas cylinder isolation valves are
open.
2. Check that the calibration gas regulators are set properly and
that the cylinder is not below the set point. If the cylinder is
below the set point, replace it with a full cylinder.
3. Verify that the calibration cylinder gas composition value listed on the cylinder tag or on the certificate of analysis received from supplier matches the calibration cylinder gas
composition value displayed in MON2020's Component Data
table. If there is a mismatch, edit the Component Data table
to reflect the correct value. Re-run the calibration sequence.
4. If still unsuccessful contact your Emerson Process Management representative.
Operation and maintenance
Operation and maintenance
4
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Operation and maintenance
Test points
Lower enclosure showing test points on the back planeFigure 4-1:
The backplane has a set of test points that allow you to measure the voltage output of the
Base I/O card. Each test point is labeled with a voltage value that, when measured with a
voltmeter, should give a measurement equal to what is displayed on the label. A reading
that does not match this label may indicate a faulty Base I/O card. Try swapping out the
suspect card with a different one, and take another measurement. To get a measurement
for a test point, touch the voltmeter’s negative probe to the D GND test point, and touch
the voltmeter’s positive probe to the desired test point.
The following test points are associated with the following GC components:
Test Point GC Component Tolerances
24V (Regulated) GC power ±2.4V
17V Preamp (Input for the bridge circuit) ±0.5V
12V Optional I/O cards ±0.6V
5V1 System chips ±0.25V
3.3V System chips ±0.15V
FVIN, F GND Field voltage input and ground ±0V - 3V (21v - 30v)
SV1, SV2 Solenoid voltages that drive the heater/solenoid card ±2.4V
The input voltage range for DC/DC power supply is between 21 and 30 volts. The input
range for AC/DC power supply is 90 - 264 volts (auto-ranging).
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Voltage LEDs
A set of LEDs can be found above the test points. These LEDs are a quick way to visually
inspect the voltage status of some of the GC’s electrical components.
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Voltage LEDsFigure 4-2:
The following LEDs are associated with the following GC components:
Operation and maintenance
Operation and maintenance
4
LED GC Component
FUSE OPEN Glows red when the fuse has blown or been removed; otherwise, it is not lit.
24 LOOP (Power) Glows green when the current loop for the analog outputs is functioning prop-
erly; otherwise, it is not lit.
24V (Regulated) Glows green when the GC power is functioning properly; otherwise, it is not lit.
17V
(Input for the
preamp)
12V
(Input for the I/O
cards)
5V1 Glows green when the System chips are functioning properly; otherwise, it is
3V Glows green when the System chips are functioning properly; otherwise, it is
POWER ON Glows green when the GC is on; otherwise, it is not lit.
Glows green when the Preamp is functioning properly; otherwise, it is not lit.
Glows green when the optional ROC expansion card is functioning properly;
otherwise, it is not lit.
not lit.
not lit.
Temperature
Use MON2020 to monitor the temperature of the detector(s) and columns to determine if
the GC is thermally stable.
When connected to the GC via MON2020, select Heaters… from the Hardware menu to
access this function. The Heaters window displays.
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Operation and maintenance
When viewing the Heater window, the typical heater configuration is as follows:
• Heater 1 is the analytical block heater.
• Heater 2 is the “high hat” heater.
The Temperature column on the Heaters window displays the current temperature; the
Current PWM column displays the percentage of power being used to run the heater.
The settings and values shown in the Heaters window and described in the table below are
preset at the factory and are based on the specific customer application. These values
should not be changed unless recommended by Application Engineering, Customer
Service personnel, or as part of a factory application requirement.
Function Typical Setting
Detector(s) or analytical block temperature 80 °C (176 °F)
Oven temperature 80 °C (176 °F)
Spare
Or, Methanator
Or, LSIV
N/A
300 °C (572 °F)
150 °C (302 °F)
FID configuration
When connected to the GC via MON2020, select Detectors from the Hardware menu to
access the Detectors dialog. Refer to the MON2020 user manual for additional
configuration details.
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Operation and maintenance
The Detectors windowFigure 4-3:
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4
Configure the following fields from the Detectors dialog:
• FID Ignition - manual or automatic
• Ignition Attempts
• Wait Time Between Tries
• Igniter ON duration
• Flame ON Sense Temperature
• Flame OUT Sense Temperature
• Electrometer Voltage
Note
If the FID does not show up in the Detectors window, disconnect from MON2020 and turn off the
GC. Inspect the S1 switch, which is located on the half-moon-shaped wire terminal board. The switch
should be set to "ON".
4.4.5 Checking the GC for leaks
Leak checking should be a standard component of any maintenance protocol. See
Section 3.6.1.
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Operation and maintenance
Plugged lines, columns, and valves
If the lines, columns, or valves are 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 lines.
• A dashed line indicates flow direction when the valve is ON, that is, energized.
• A solid line indicates flow direction when the valve is OFF, i.e., not energized.
4.4.6 Valves
Only minimal repair and maintenance is required by the customer (e.g., replacing the
diaphragms).
Required tools for valve maintenance
The tools required for performing repair and general maintenance on the XA valve
assemblies are:
• Torque wrench, scaled in foot-pounds
• 1/2” socket for 10-port valves
• 7/16” socket for 6-port valves
• 1/4” open-ended wrench
• 5/16” open-ended wrench
• 5/32” allen wrench
Valve replacement parts
Replacement parts required for each XA valves consist of the following parts:
• Diaphragm Kit 6-port XA Valve (P/N 2-4-0710-248)
• Diaphragm Kit 10-port XA Valve (P/N 2-4-0710-171)
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XA valvesFigure 4-4:
Valve overhaul
Operation and maintenance
Operation and maintenance
4
Note
Replacement factory-built XA valves are available. Call your Emerson Process Management
representative for more information.
Use the following procedure to overhaul a valve:
1. If you are overhauling a 6-port valve, refer to drawing #CE-22015; If you are
overhauling a 10-port valve, refer to drawing #CE-22016. Both drawings are
available in Appendix F.
2. Shut off the carrier and sample gas streams entering the unit.
3. Remove the top hat heater from the oven system.
4. If the faulty valve is not easily accessible, loosen the thumb screw and tilt the oven
on its side.
5. Disconnect tubing and fittings that attach to the valve from other locations.
6. Use an allen wrench to remove the two baseplate bolts on the valve to be replaced
or serviced. The valve can now be removed from the GC.
7. Loosen the valve’s torque bolt.
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Operation and maintenance
8. Holding the lower piston plate, pull the valve straight off the block. The alignment
9. Remove and discard the old valve diaphragms and gaskets.
10. Clean the sealing surface as required using a non-lint-forming cloth and isopropyl
The torque boltFigure 4-5:
pins may stick slightly.
alcohol. Blow the sealing surface with clean, dry instrument air or carrier gas. Dirt
including dust and lint can cause troublesome leakage.
Note
Do not use an oil-based cleaner on the valve.
11. Replace the old diaphragms and gaskets, in the same order, with the new ones
supplied.
12. Reinstall the valve using the following steps:
a. Align the pins with holes in the block and push the valve assembly into place.
b. Tighten the valve’s torque bolt. The 6-port valve requires 20 ft/lb of torque; the
10-port valve requires 30 ft/lb of torque.
c. Return the valve to the assembly.
d. Reconnect all fittings and tubing.
Removing and replacing solenoids
Both the oven system solenoids and the stream switching solenoids can be replaced by
using the following procedure.
WARNING!
Disconnect all electrical power to the unit and ensure the area is free of explosive gases. Failure
to follow this warning may result in injury or death to personal or cause damage to the
equipment.
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