Emerson MicroCEM User Manual
Instruction Manual
748467-A
January 2002
Model MicroCEM
Continuous Emissions Monitor
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and
international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and integrated into your
safety program when installing, using, and maintaining Rosemount Analytical products. Failure to
follow the proper instructions may cause any one of the following situations to occur: Loss of life;
personal injury; property damage; damage to this instrument; and warranty invalidation.
•
Read all instructions prior to installing, operating, and servicing the product.
If you do not understand any of the instructions, contact your Rosemount Analytical repre-
•
sentative for clarification.
Follow all warnings, cautions, and instructions marked on and supplied with the product.
•
Inform and educate your personnel in the proper installation, operation, and maintenance of the
•
product.
Install your equipment as specified in the Installation Instructions of the appropriate Instruction
•
Manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources.
To ensure proper performance, use qualified personnel to install, operate, update, program,
•
and maintain the product.
When replacement parts are required, ensure that qualified people use replacement parts speci-
•
fied by Rosemount. Unauthorized parts and procedures can affect the product’s performance,
place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike
substitutions may result in fire, electrical hazards, or improper operation.
•
Ensure that all equipment doors are closed and protective covers are in place, except
when maintenance is being performed by qualified persons, to prevent electrical shock
and personal injury.
The information contained in this document is subject to change without notice.
Logos, trademarks and copyrights are property of their respective owners.
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 North Main Street
Orrville, Ohio 44667-09012
T (330) 682-9010
F (330) 684-4434
e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com
Model MicroCEM
PREFACE...........................................................................................................................................P-1
Definitions ...........................................................................................................................................P-1
Intended Use Statement.....................................................................................................................P-2
Safety Summary .................................................................................................................................P-2
General Precautions For Handling And Storing High Pressure Gas Cylinders .................................P-5
Documentation....................................................................................................................................P-6
Compliances .......................................................................................................................................P-6
1-0 DESCRIPTION AND SPECIFICATIONS..............................................................................1-1
1-1 Overview................................................................................................................................1-1
1-2 Typical Applications...............................................................................................................1-1
1-3 Theory Of Operation..............................................................................................................1-1
a. Chemiluminescense NOX................................................................................................1-1
b. Non-Dispersive Infrared (NDIR) CO ...............................................................................1-1
c. Paramagnetic O2.............................................................................................................1-2
1-4 Detector Methodologies.........................................................................................................1-2
a. Non-Dispersive Infrared (NDIR)......................................................................................1-2
b. Paramagnetic Oxygen Method .......................................................................................1-6
c. Electrochemical Oxygen Method ....................................................................................1-7
1-5 Central Processing Unit.........................................................................................................1-9
a. Embedded Enhanced Bios .............................................................................................1-9
b. Specifications ..................................................................................................................1-9
1-6 Analog/Digital I/O Board ........................................................................................................1-10
a. Automatic Calibration......................................................................................................1-10
b. Analog Inputs ..................................................................................................................1-10
c. Programmable Input Ranges ..........................................................................................1-11
d. Enhanced Trigger and Sampling Control Signals...........................................................1-11
e. Analog Outputs ...............................................................................................................1-11
f. FIFO and 16-Bit Bus Interface ........................................................................................1-11
g. Specifications ..................................................................................................................1-13
1-7 PCMCIA Adapter ...................................................................................................................1-14
a. Features ..........................................................................................................................1-14
b. Software ..........................................................................................................................1-14
1-8 Modem...................................................................................................................................1-15
a. Features ..........................................................................................................................1-15
1-9 Flash Drive.............................................................................................................................1-16
a. Specifications ..................................................................................................................1-16
1-10 Pocket PC..............................................................................................................................1-18
a. Specifications ..................................................................................................................1-18
1-11 Wireless LAN Adapter ...........................................................................................................1-19
a. Specifications ..................................................................................................................1-19
1-12 500 Watts Power Supply .......................................................................................................1-20
a. Features ..........................................................................................................................1-20
1-13 MicroCEM Specifications.......................................................................................................1-21
a. Analyzer ..........................................................................................................................1-21
b. Probe/Sample Handling ..................................................................................................1-22
Instruction Manual
748467-A
January 2002
TABLE OF CONTENTS
Rosemount Analytical Inc. A Division of Emerson Process Management Contents i
Instruction Manual
748467-A
January 2002
2-0 INSTALLATION ....................................................................................................................2-1
2-1 Overview................................................................................................................................2-1
a. Limitations .......................................................................................................................2-1
b. Mounting Options ............................................................................................................2-1
2-2 Location .................................................................................................................................2-1
2-3 Gases ....................................................................................................................................2-3
a. Connection ......................................................................................................................2-3
b. Conditioning ....................................................................................................................2-3
2-4 Electrical Connections ...........................................................................................................2-6
a. AC Power ........................................................................................................................2-8
b. Circular Connector Assembly Instructions......................................................................2-8
c. Interface Connections .....................................................................................................2-11
2-5 Analytical Leak Check ...........................................................................................................2-14
a. Flow Indicator Method.....................................................................................................2-14
b. Manometer Method.........................................................................................................2-15
3-0 OPERATION .........................................................................................................................3-1
3-1 Startup Procedure .................................................................................................................3-1
3-2 Pocket PC User Interface ......................................................................................................3-1
a. Connecting Pocket PC to MicroCEM ..............................................................................3-1
b. Main Display....................................................................................................................3-3
c. MicroCEM Menu .............................................................................................................3-4
d. MicroCEM Alarms ...........................................................................................................3-4
e. MicroCEM Login..............................................................................................................3-6
f. MicroCEM Login-Current User Indication .......................................................................3-6
3-3 MicroCEM Settings................................................................................................................3-7
a. Range..............................................................................................................................3-7
b. Auto Calibration...............................................................................................................3-8
c. Auto Calibration Time and Frequency ............................................................................3-8
d. Manual Calibration ..........................................................................................................3-9
e. Limits...............................................................................................................................3-10
f. Calibration Gas ...............................................................................................................3-10
g. Maintenance Mode .........................................................................................................3-11
3-4 MicroCEM Factory Settings...................................................................................................3-12
a. PID Control Loop Factory Settings .................................................................................3-15
3-5 MicroCEM Administration ......................................................................................................3-17
a. User Settings...................................................................................................................3-17
b. Auto Logoff......................................................................................................................3-17
3-6 MicroCEM Data Logs ............................................................................................................3-18
a. Maximum Log File Size...................................................................................................3-18
b. Maximum Number of Log Files .......................................................................................3-18
c. Log File Name Format ....................................................................................................3-18
d. Measurement Log File Format........................................................................................3-18
e. Calibration Log File Format.............................................................................................3-19
f. Alarm Log File Format ....................................................................................................3-20
3-7 View Data Logs .....................................................................................................................3-21
3-8 Viewing MicroCEM Data with a Web Browser ......................................................................3-23
a. Real-Time Page ..............................................................................................................3-23
b. Emissions Page ..............................................................................................................3-24
c. Download Page ...............................................................................................................3-26
3-9 Viewing MicroCEM Data with MS Excel................................................................................3-27
3-10 Auto Calibration .....................................................................................................................3-28
Model MicroCEM
ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model MicroCEM
4-0 SOFTWARE ..........................................................................................................................4-1
4-1 Overview................................................................................................................................4-1
4-2 MicroCEM User Interface Software .......................................................................................4-1
4-3 MicroCEM Web Server Software ..........................................................................................4-1
4-4 Software Development Management ....................................................................................4-2
5-0 MAINTENANCE AND SERVICE ..........................................................................................5-1
5-1 Overview................................................................................................................................5-1
5-2 Converter ...............................................................................................................................5-3
5-3 Ozone Generator...................................................................................................................5-4
5-4 Personality Modules ..............................................................................................................5-4
5-5 Chemiluminescense Detector Assembly...............................................................................5-5
a. Reaction Chamber ..........................................................................................................5-5
b. Photodiode ......................................................................................................................5-5
6-0 TROUBLESHOOTING ..........................................................................................................6-1
6-1 Troubleshooting Leaks ..........................................................................................................6-1
6-2 Pocket PC Connection Failure ..............................................................................................6-1
6-3 Trouble LED ..........................................................................................................................6-1
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January 2002
7-0 REPLACEMENT PARTS ......................................................................................................7-1
8-0 RETURN OF MATERIAL ......................................................................................................8-1
8-1 Return Of Material .................................................................................................................8-1
8-2 Customer Service ..................................................................................................................8-1
8-3 Training..................................................................................................................................8-1
Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii
Instruction Manual
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January 2002
Figure 1-1. Absorption Bands of Sample Gas and Transmittance of Interference Filters ....... 1-3
Figure 1-2. Opto-Pneumatic Gas Detector............................................................................... 1-4
Figure 1-3. Overall NDIR Method............................................................................................. 1-5
Figure 1-4. Paramagnetic Oxygen Analysis............................................................................. 1-6
Figure 1-5. Reaction of Galvanic Cell ...................................................................................... 1-7
Figure 1-6. Electrochemical Oxygen Sensor............................................................................ 1-8
Figure 1-7. CPU ....................................................................................................................... 1-9
Figure 1-8. ADIO Board.......................................................................................................... 1-10
Figure 1-9. ADIO Block Diagram............................................................................................ 1-12
Figure 1-10. PCMCIA Interface................................................................................................ 1-14
Figure 1-11. Modem................................................................................................................. 1-15
Figure 1-12. 128MB Flash Drive .............................................................................................. 1-16
Figure 1-13. Pocket PC............................................................................................................ 1-18
Figure 1-14. Wireless LAN adapter.......................................................................................... 1-19
Figure 1-15. 500 Watts Power Supply ..................................................................................... 1-20
Figure 2-1. MicroCEM Outline and Mounting Dimensions....................................................... 2-2
Figure 2-2. MicroCEM Gas Connections ................................................................................. 2-4
Figure 2-3. MicroCEM Flow Diagram....................................................................................... 2-4
Figure 2-4. MicroCEM Installation and Test Setup Configuration............................................ 2-5
Figure 2-5. MicroCEM Electrical Connections ......................................................................... 2-6
Figure 2-6. MicroCEM Wiring Diagram .................................................................................... 2-7
Figure 2-7. Leak Test Flow Method ....................................................................................... 2-14
Figure 2-8. Leak Test Manometer Method............................................................................. 2-15
Figure 3-1. Pocket PC .............................................................................................................. 3-1
Figure 3-2. MicroCEM Front Panel .......................................................................................... 3-2
Figure 3-3. MicroCEM Pocket PC Display (Main Display Shown) ........................................... 3-3
Figure 3-4. MicroCEM Menu .................................................................................................... 3-4
Figure 3-5. Pocket PC Alarms Screen ..................................................................................... 3-4
Figure 3-6. MicroCEM Login .................................................................................................... 3-6
Figure 3-7. Current User Indication.......................................................................................... 3-6
Figure 3-8. Range Settings ...................................................................................................... 3-7
Figure 3-9. Auto Calibration Settings ....................................................................................... 3-8
Figure 3-10. Auto Calibration Time and Frequency ................................................................... 3-8
Figure 3-11. Manual Calibration................................................................................................. 3-9
Figure 3-12. Manual Calibration Results.................................................................................... 3-9
Figure 3-13. Limit Settings ....................................................................................................... 3-10
Figure 3-14. Calibration Gas Settings...................................................................................... 3-10
Figure 3-15. Maintenance Mode Settings ................................................................................ 3-11
Figure 3-16. User Settings .......................................................................................................3-17
Figure 3-17. Auto Logoff........................................................................................................... 3-17
Figure 3-18. View Data Logs.................................................................................................... 3-21
Figure 3-19. View Data Logs Table.......................................................................................... 3-22
Figure 3-20. Real-Time Web Page .......................................................................................... 3-23
Figure 3-21. Emissions Selection............................................................................................. 3-24
Figure 3-22. Emissions Table .................................................................................................. 3-24
Figure 3-23. Calibration Table.................................................................................................. 3-25
Figure 3-24. Download Web Page ........................................................................................... 3-26
Figure 3-25. New Web Query .................................................................................................. 3-27
Figure 3-26. Auto Calibration ................................................................................................... 3-28
Figure 4-1. MicroCEM Software Block Diagram ...................................................................... 4-1
Figure 5-1. MicroCEM Component Location............................................................................ 5-2
Model MicroCEM
LIST OF ILLUSTRATIONS
iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model MicroCEM
Figure 5-2. Converter Assembly .............................................................................................. 5-3
Figure 5-3. Personality Modules and Backplane. .................................................................... 5-4
Figure 5-4. Chemiluminescense Detector Assembly ............................................................... 5-6
Figure 5-5. Chemiluminescense Detector Assembly – Exploded View ................................... 5-7
Table 2-1. Interface Connections.......................................................................................... 2-11
Table 2-2. AC Power Connection Terminal Assignments..................................................... 2-11
Table 2-3. Analog Output Terminal Assignments ................................................................. 2-11
Table 2-4. Digital Output Terminal Assignments .................................................................. 2-12
Table 2-5. RS-232 Interface Terminal Assignments............................................................. 2-13
Table 2-6. RS-485 Terminal Assignments............................................................................ 2-13
Table 2-7. LAN Interface Terminal Assignments .................................................................. 2-13
Table 2-8. Phone Line (Modem) Terminal Assignments ...................................................... 2-13
Table 2-9. Antenna (Peltier Power) Connection Terminal Assignments .............................. 2-14
Table 3-1. Status Values.........................................................................................................3-3
Table 3-2. Alarm Summary ..................................................................................................... 3-5
Table 3-3. Factory Settings – Calibration.............................................................................. 3-13
Table 3-4. Factory Settings - General................................................................................... 3-14
Table 3-5. PID Settings – Section Names ............................................................................ 3-15
Table 3-6. PID Settings – Sections Descriptions .................................................................. 3-16
Table 3-7. Measurement Log File Format............................................................................. 3-18
Table 3-8. Calibration Log File Format ................................................................................. 3-19
Table 3-9. Alarm Log File Format ......................................................................................... 3-20
Table 3-10. Average Period Selection .................................................................................... 3-21
Instruction Manual
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January 2002
LIST OF TABLES
Rosemount Analytical Inc. A Division of Emerson Process Management Contents v
Instruction Manual
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January 2002
Model MicroCEM
vi Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model MicroCEM
PREFACE
The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the MicroCEM.
Some sections may describe equipment not used in your configuration. The user should become
thoroughly familiar with the operation of this module before operating it. Read this instruction
manual completely.
DEFINITIONS
The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout
this publication.
DANGER .
Highlights the presence of a hazard which will cause severe personal injury, death, or substantial
property damage if the warning is ignored.
748467-A
January 2002
WARNING .
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
CAUTION.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.
NOTE
Highlights an essential operating procedure,
condition or statement.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1
Instruction Manual
748467-A
January 2002
Model MicroCEM
INTENDED USE STATEMENT
The MicroCEM Continuous Emissions Monitor is intended for use as an industrial process measurement device only. It is not intended for use in medical, diagnostic, or life support applications,
and no independent agency certifications or approvals are to be implied as covering such applications.
SAFETY SUMMARY
If this equipment is used in a manner not specified in these instructions, protective systems may be
impaired.
AUTHORIZED PERSONNEL
To avoid explosion, loss of life, personal injury and damage to this equipment and on-site property,
do not operate or service this instrument before reading and understanding this instruction manual
and receiving appropriate training. Save these instructions.
DANGER.
ELECTRICAL SHOCK HAZARD
Do not open while energized. Installation requires access to live parts which can cause death or
serious injury.
For safety and proper performance this instrument must be connected to a properly grounded
three-wire source of power.
DANGER.
POSSIBLE EXPLOSION HAZARD
Do not operate without covers secure. Ensure that all gas connections are made as labeled and are
leak free. Improper gas connections could result in explosion and death.
P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model MicroCEM
DANGER.
TOXIC GAS
This device may contain explosive, toxic or unhealthy gas components. Before cleaning or changing parts in the gas paths, purge the gas lines with ambient air or nitrogen.
This unit’s exhaust may contain hydrocarbons and other toxic gases such as carbon monoxide.
Carbon monoxide is highly toxic and can cause headache, nausea, loss of consciousness, and
death.
WARNING: TOXIC GAS
Avoid inhalation of the exhaust gases at the exhaust fitting.
Connect exhaust outlet to a safe vent using stainless steel or Teflon line. Check vent line and connections for leakage.
Keep all tube fittings tight to avoid leaks. See Sections 2-5 for leak check information.
WARNING.
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January 2002
DEVICE HAZARDOUS AREA CERTIFICATION(S)
Any addition, substitution, or replacement of components installed on or in this device, must be
certified to meet the hazardous area classification that the device was certified to prior to any such
component addition, substitution, or replacement. In addition, the installation of such device or
devices must meet the requirements specified and defined by the hazardous area classification of
the unmodified device. Any modifications to the device not meeting these requirements, will void
the product certification(s).
WARNING.
PARTS INTEGRITY AND UPGRADES
Tampering with or unauthorized substitution of components may adversely affect the safety of this
instrument. Use only factory approved components for repair.
Because of the danger of introducing additional hazards, do not perform any unauthorized modification to this instrument.
Return the instrument to Rosemount Analytical Customer Service Center. See Section 8.
CAUTION.
PRESSURIZED GAS
This unit requires periodic calibration with a known standard gas. It also may utilizes a pressurized carrier gas, such as helium, hydrogen, or nitrogen. See General Precautions for Handling and
Storing High Pressure Gas Cylinders, page P-5.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3
Instruction Manual
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January 2002
CAUTION.
HEAVY WEIGHT
Use two persons or a suitable lifting device to move or carry the instrument.
Model MicroCEM
P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
748467-A
Model MicroCEM
January 2002
GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH
PRESSURE GAS CYLINDERS
Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed
Gases" published in 1981
Compressed Gas Association
1235 Jefferson Davis Highway
Arlington, Virginia 22202
Used by Permission
1. Never drop cylinders or permit them to strike each other violently.
2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of
weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the
shade when located in areas where extreme temperatures are prevalent.
3. The valve protection cap should be left on each cylinder until it has been secured against a wall or
bench, or placed in a cylinder stand, and is ready to be used.
4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a
suitable hand-truck.
5. Never tamper with safety devices in valves or cylinders.
6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is
attached to a pressurized system.
7. No part of cylinder should be subjected to a temperature higher than 125°F (52°C). A flame should
never be permitted to come in contact with any part of a compressed gas cylinder.
8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding,
precautions must be taken to prevent striking an arc against the cylinder.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5
Instruction Manual
748467-A
January 2002
Model MicroCEM
DOCUMENTATION
The following MicroCEM instruction materials are available. Contact Customer Service Center or the local representative to order (See Section 8).
748467 Instruction Manual (this document)
748468 Instruction Manual, MicroCEM Sample Handling System
COMPLIANCES
This product may carry approvals from several certifying agencies. The certification marks appear on the
product name-rating plate.
CSA (Pending)
P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model MicroCEM
DESCRIPTION AND SPECIFICATIONS
1-1 OVERVIEW
The MicroCEM Analyzer Module is designed
to continuously determine the concentration of
, CO, and NOx in a flowing gaseous mix-
O
2
ture. The concentration is expressed in percent (%) or parts-per-million (PPM).
SECTION 1
Instruction Manual
748467-A
January 2002
and oxygen (O2). Some of the NO
NO
2
molecules produced are in an electronically excited state (NO
* where the * re-
2
fers to the excitation). These revert to the
ground state, with emission of photons
(essentially, red light). The reactions involved are:
2
The sampled gas is collected from the stack
and prepared by the Probe/Sample Handling
System for analysis and processing by the
Analysis Enclosure. The Analysis Enclosure
shall be a standalone, computer-controlled
unit, utilizing PC/104 as the system bus.
The MicroCEM is enclosed in a rugged NEMA
4X, IP65 type enclosure, for harsh environment. The analysis enclosure utilizes convection cooling with no air intake and air vents.
The analysis enclosure is modular, general
purpose and easily expandable. It utilizes industry standard components such as PC/104
boards, and modular signal conditioning modules.
1-2 TYPICAL APPLICATIONS
SCR
Emission Compliance per EPA 40 CFR Part
60
Gas Turbines
Natural Gas Fired Boilers
Process Heaters
NO2 + O3 → NO2* + O
2
NO2* → NO2 + red light
The sample is continuously passed
through a heated bed of vitreous carbon,
in which NO
is reduced to NO. Any NO
2
initially present in the sample passes
through the converter unchanged, and
any NO
is converted to an approximately
2
equivalent (95%) amount of NO.
The NO is quantitatively converted to NO
by gas-phase oxidation with molecular
ozone produced within the analyzer form
air supplied by an external source. During
the reaction, approximately 10% of the
NO
molecules are elevated to an elec-
2
tronically excited state, followed by immediate decay to the non-excited state,
accompanied by emission of photons.
These photons are detected by a photomultiplier tube which produces an output
proportional to the concentration of NOx
in the sample.
2
1-3 THEORY OF OPERATION
To minimize system response time, an
internal sample bypass feature provides
a. Chemiluminescense NO
X
high-velocity sample flow through the
analyzer.
The NOx analyzer continuously analyzes
a flowing gas sample for NOx [nitric oxide
(NO) plus nitrogen dioxide (NO
)]. The
2
sum of the concentrations is continuously
reported as NOx.
b. Non-Dispersive Infrared (NDIR) CO
The optical bench can selectively meas-
ure multiple components in a compact
design by using a unique dual optical
The MicroCEM NOx Analyzer Module
uses the chemiluminescense method of
detection. This technology is based on
NO’s reaction with ozone (O
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
) to produce
3
bench design. Depending on the applica-
tion, any two combinations of NDIR chan-
nels can be combined on a single
chopper motor/dual source assembly.
Instruction Manual
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January 2002
Model MicroCEM
Other application-dependent options include a wide range of sample cell materials, optical filters and solid state
detectors. The NDIR Microflow detector
consists of two chambers, measurement
and reference with an interconnected path
in which an ultra low flow filament sensor
is mounted. During operation, a pulsating
flow occurs between the two chambers
which is dependent upon: sample gas absorption, modulation by the chopper motor and the fill gas of the detector
chambers. The gas flow/sensor output is
proportional to the measured gas concentration. The optical bench is further
enhanced by a novel “Look-through” detector technique. This design allows two
detectors to be arranged in series --- enabling two different components to be
measured on a single optical bench. The
optical bench contains a unique eddy current drive chopper motor and source assembly. This design incorporates on
board “intelligence” to provide continuous
“self test” diagnostics.
c. Paramagnetic O2
measured. The gas-specific wavelengths
of the absorption bands characterize the
type of gas while the strength of the ab-
sorption gives a measure of the concen-
tration of the gas component being
measured.
An optical bench is employed comprising
an infrared light source, two analysis cells
(reference and measurement), a chopper
wheel to alternate the radiation intensity
between the reference and measurement
side, and a photometer detector. The de-
tector signal thus alternates between con-
centration dependent and concentration
independent values. The difference be-
tween the two is a reliable measure of the
concentration of the absorbing gas com-
ponent.
Depending on the gas being measured
and its concentration, one of two different
measuring methods may be used as fol-
lows:
Interference Filter Correlation (IFC)
Method
The determination of oxygen is based on
the measurement of the magnetic susceptibility of the sample gas. Oxygen is
strongly paramagnetic, while other common gases are not. The detector used is
compact, has fast response and a wide
dynamic range. The long life cell is corrosion resistant, heated and may be easily
cleaned. It has rugged self-tensioning
suspension and is of welded non-glued
construction.
1-4 DETECTOR METHODOLOGIES
The MicroCEM can employ up to three different measuring methods depending on the
configuration chosen. The methods are:
NDIR, Paramagnetic O
and Chemiluminescense.
a. Non-Dispersive Infrared (NDIR)
The non-dispersive infrared method is
based on the principle of absorption of infrared radiation by the sample gas being
, Electrochemical O2,
2
With the IFC method the analysis cell is
alternately illuminated with filtered infrared
concentrated in one of two spectrally
separated wavelength ranges. One of
these two wavelength bands is chosen to
coincide with an absorption band of the
sample gas and the other is chosen such
that none of the gas constituents ex-
pected to be encountered in practice ab-
sorbs anywhere within the band.
The spectral transmittance curves of the
interference filters used in the MicroCEM
analyzer and the spectral absorption of
the gases CO and CO
ure 1-1. It can be seen that the absorption
bands of these gases each coincide with
the passbands of one of the interference
filters. The forth interference filter, used
for generating a reference signal, has its
passband in a spectral region where none
of these gases absorb. Most of the other
gases of interest also do not absorb within
the passband of this reference filter.
are shown in Fig-
2
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model MicroCEM
The signal generation is accomplished
with a pyroelectrical (solid-state) detector.
The detector records the incoming infrared radiation. This radiation is reduced by
the absorption of the gas at the corresponding wavelengths. By comparing the
measurement and reference wavelength,
an alternating voltage signal is produced.
This signal results from the cooling and
heating of the pyroelectric detector material.
Instruction Manual
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January 2002
CO
2
Transmittance (%)
0 15 30 54 60 75 90
Transmittance (%)
0 18 36 54 72 90
3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600
HC CO2 CO
Reference
Wave Length (nm)
CO
Absorption Band
Figure 1-1. Absorption Bands of Sample Gas and Transmittance of Interference Filters
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
Instruction Manual
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January 2002
Opto-Pneumatic Method
Model MicroCEM
In the opto-pneumatic method, a thermal
radiator generates the infrared radiation
which passes through the chopper wheel.
This radiation alternately passes through
the filter cell and reaches the measuring
and reference side of the analysis cell
with equal intensity. After passing another
filter cell, the radiation reaches the pneumatic detector.
The pneumatic detector compares and
evaluates the radiation from the measuring and reference sides of the analysis
cell and converts them into voltage signals proportional to their respective intensity.
The pneumatic detector consists of a gasfilled absorption chamber and a compensation chamber which are connected by a
flow channel in which a Microflow filament
sensor is mounted. This is shown in Figure 1-2.
In principle the detector is filled with the
infrared active gas to be measured and is
only sensitive to this distinct gas with its
characteristic absorption spectrum. The
absorption chamber is sealed with a window which is transparent for infrared radiation. The window is usually Calcium
Fluoride (CaF
).
2
When the infrared radiation passes
through the reference side of the analysis
cell into the detector, no pre-absorption
occurs. Thus, the gas inside the absorp-
tion chamber is heated, expands and
some of it passes through the flow chan-
nel into the compensation chamber.
When the infrared radiation passes
through the open measurement side of
the analysis cell into the detector, a part
of it is absorbed depending on the gas
concentration. The gas in the absorption
chamber is, therefore, heated less than in
the case of radiation coming from the ref-
erence side. Absorption chamber gas be-
comes cooler, gas pressure in the
absorption chamber is reduced and some
gas from the compensation chamber
passes through the flow channel into the
absorption chamber.
The flow channel geometry is designed in
such a way that it hardly impedes the gas
flow by restriction. Due to the radiation of
the chopper wheel, the different radiation
intensities lead to periodically repeated
flow pulses within the detector.
The Microflow sensor evaluates these
flow pulses and converts them into elec-
trical pulses which are processed into the
corresponding analyzer output.
Absorption chamber
Flow channel with
Microflow sensor
CaF2 Window
Compensation chamber
Figure 1-2. Opto-Pneumatic Gas Detector
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model MicroCEM
Instruction Manual
748467-A
January 2002
Overall NDIR Method
In the case of dual-channel analyzers, the
broadband emission from two infrared
sources pass through the chopper wheel.
In the case of the Interference Filter Correlation (IFC) method, the infrared radiation then passes through combinations of
interference filters. In the case of the
opto-pneumatic method, the infrared radiation passes through an optical filter
Light Source
Chopper Blade
MOTOR
depending on the application and need for
reduction of influences. Then the infrared
radiation enters the analysis cells from
which it is focused by filter cells onto the
corresponding detector. The preamplifier
detector output signal is then converted
into the analytical results expressed di-
rectly in the appropriate physical concen-
tration units such as percent volume,
ppm, mg/Nm
3
, etc. This is shown in Fig-
ure 1-3.
Duplex Filter Disc
Adapter Cell
(high measuring range)
Analysis Cell
(measuring side)
Analysis Cell
(reference side)
Filter Cell
Gas Detector
Analysis Cell
(undivided)
Filter Cell
Preamplifier
Pyroelectric Detector
(solid-state detector)
Preamplifier
Chopper Blade
Figure 1-3. Overall NDIR Method
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5
Instruction Manual
748467-A
January 2002
Model MicroCEM
b. Paramagnetic Oxygen Method
The paramagnetic principle refers to the
induction of a weak magnetic field, parallel and proportional to the intensity of a
stronger magnetizing field.
The paramagnetic method of determination of oxygen concentration utilizes nitrogen filled quartz spheres arranged at
opposite ends of a bar, the center of
which is suspended by and free to rotate
on a thin platinum wire ribbon in a cell.
Nitrogen (N
) is used because it is dia-
2
magnetic or repelled by a magnet.
A small mirror that reflects a light beam
coming from a light source to a photodetector, is mounted on the platinum ribbon.
A strong permanent magnet specifically
shaped to produce a strong, highly inhomogeneous magnetic field inside the
analysis cell, is mounted outside the wall
of the cell.
When oxygen molecules enter the cell,
their paramagnetism will cause them to
be drawn towards the region of greatest
magnetic field strength. The oxygen
molecules thus exert different forces on
the two suspended nitrogen filled quartz
spheres, producing a torque which
causes the mirror to rotate away from its
equilibrium position.
The rotated mirror deflects the incident
light onto the photodetector creating an
electrical signal which is amplified and fed
back to a coil attached to the bar holding
the quartz spheres, forcing the suspended
spheres back to the equilibrium position.
The current required to generate the re-
storing torque to return the quartz bar to
its equilibrium position is a direct measure
of the O
concentration in the sample gas.
2
The complete paramagnetic analysis cell
consists of an analysis chamber, perma-
nent magnet, processing electronics, and
a temperature sensor. The temperature
sensor is used to control a heat ex-
changer to warm the measuring gas to
about 55 °C. Refer to Figure 1-4.
Light
Source
Display
Permanent Magnet
Platinum Wire
Mirror
Quartz Sphere(s)
Wire Loop
Photodetector
Amplifier
Figure 1-4. Paramagnetic Oxygen Analysis
1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model MicroCEM
Instruction Manual
748467-A
January 2002
c. Electrochemical Oxygen Method
The electrochemical method of determining oxygen concentration is based on the
galvanic cell principle shown in Figure
1-5.
The electrochemical oxygen sensor (Figure 1-6) incorporates a lead and gold galvanic process with a lead anode and a
gold cathode, using an acid electrolyte.
Oxygen molecules diffuse through a nonporous Teflon membrane into the electrochemical cell and are reduced at the gold
cathode. Water is the byproduct of this
reaction.
On the anode, lead oxide is formed which
is transferred into the electrolyte. The lead
anode is continuously regenerated and,
therefore, the electrode potential remains
unchanged for a long time. The rate of
diffusion and corresponding response
time (t90) of the sensor is dependent on
the thickness of the Teflon membrane.
The electric current between the elec-
trodes is proportional to the O
concentra-
2
tion in the sample gas being measured.
The resultant signal is measured as a
voltage across the resistor and thermistor,
the latter of which is used for temperature
compensation. A change in the output
voltage (mV) represents oxygen concen-
tration.
NOTE
The electrochemical O2 cell requires a
minimum internal consumption of
oxygen. Sample gases with an oxygen
concentration of less than 2% could
result in a reversible detuning of sensi-
tivity and the output will become un-
stable. The recommended practice is
to purge the cell with conditioned am-
bient air between periods of measure-
ment. If the oxygen concentration is
below 2% for several hours or days,
the cell must be regenerated for about
one day with ambient air. Temporary
flushing with nitrogen (N
) for less than
2
one hour (analyzer zeroing) will have
no effect on the sensitivity or stability.
(Red) V out (Black)
Thermistor (5) Resistor (6)
(-) (+)
Gold Lead
Cathode (2) Anode (1)
O2 + 4 H + 4 e → 2 H2O2 Pb + 2 H
Electrolyte (3)
(ph 6)
Summary reaction O
+ 2 Pb → 2 PbO
2
O → 2PbO + 4 H + 4 e
2
Figure 1-5. Reaction of Galvanic Cell
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7
Instruction Manual
748467-A
January 2002
Lead Wire (Anode)
Lead Wire (Cathode)
Anode (Lead)
O-Ring
Plastic Disc
Model MicroCEM
Black
Red
Plastic Disk
Resistor
Thermistor
Acid Electrolyte
Sponge Disc
Cathode (Gold Film)
Teflon Membrane
Figure 1-6. Electrochemical Oxygen Sensor
1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model MicroCEM
Instruction Manual
748467-A
January 2002
1-5 CENTRAL PROCESSING UNIT
The CPU is an Embedded Pentium-like AT
Computer in 5.75” x 8” form factor. The peripherals integrated on board are: SVGA, 4
serial ports and one parallel port, Fast
Ethernet ctrl., IDE, Keyboard, Mouse, 2 USB.
The module is built around the Intel Tillamook
processor and is equipped with 64MB
SDRAM. The module also integrates one
socket for SSD that performs like an HDD unit
and can be used to store the operating system, the user’s programs and the data files.
Other peripherals available on board are the
Floppy disk controller, the parallel port. The
CPU is shown in Figure 1-7.
a. Embedded Enhanced Bios
Award, 256KB Flash Bios.The Bios is
immediately activated when you first turn
on the system. The Bios reads system
configuratio information in CMOS RAM
and begins the process of checking out
the system.
Figure 1-7. CPU
b. Specifications
Architecture: ................................. PC/AT Compatible
Dimensions: .................................. 5.75” x 8”
Processor: .................................... Intel Tillamook processor - 266MHz
Memory: ........................................ 64 MB SDRAM
Ram/Rom disk: ............................. 1 x 32 pin socket (max. 288MB)
Operating System: ........................ WinNT
BIOS: ............................................ Standard with embedded extensions
Interfaces: ..................................... IDE ctrl
Floppy ctrl
SVGA-CRT
10/100 Mbps Fast Ethernet
2 USB ports
4 RS232 serial ports (one can be 485)
Parallel port (bi-directional EPP-ECP)
Keyboard PS/2
Mouse PS/2
Bus: .............................................. AT bus according to PC/104 spec.
Power Supply: .............................. AT/ATX
Connectors: .................................. COM1-4, SVGA, USB 1 and 2, PS/2 Mouse/Keyboard, ATX Power,
Parallel, IDE, Floppy, and Fast Ethernet
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-9
Instruction Manual
748467-A
January 2002
1-6 ANALOG/DIGITAL I/O BOARD
The Analog/Digital IO (ADIO) Board is an offthe-shelf, complete data acquisition system in
a compact PC/104 packaging. The analog
section contains 32 input channels, multiplexed A/D converter with 16 bit resolution
and 10uS conversion time. Input ranges are
+/-5v or +/- 10V. It also includes on-board
DMA support. The analog output section includes two 12 bit D/A converters. Both sections features simplified calibration using on
board programmable digital potentiometer.
The digital I/O section provides 24 digital I/O
lines, which feature high current TTL drivers.
The board requires only +5V from the system
power supply and generates its own +/-15V
analog supplies on board. The board operates
over the Extended Temperatures range of -25
to +85C. Figure 1-8 depicts the ADIO board
and Figure 1-9 depicts the ADIO block diagram.
Model MicroCEM
a. Automatic Calibration
The ADIO board features automatic cali-
bration of both analog inputs and outputs
for enhanced accuracy and reliability. The
potentiometers, which are subject to tam-
pering and vibration, have been elimi-
nated. Instead, all A/D calibration
adjustments are performed using an octal
8-bit DAC. The DAC values are stored in
an EEPROM and are recalled automati-
cally on power up. The board includes
three precision voltage references for
negative full scale, zero, and positive full-
scale. A calibration utility program pro-
vided with the board allows you to recali-
brate the board anytime, in both unipolar
and bipolar modes, and store the new
settings in EEPROM.
Autocalibration applies to the 4 D/A chan-
nels as well. The full-scale D/A range is
selected with a jumper block. The analog
outputs are fed back to the A/D converter
so they can be calibrated without user in-
tervention. Again, calibration settings are
stored in EEPROM and automatically re-
called on power-up.
Figure 1-8. ADIO Board
b. Analog Inputs
The ADIO board provides split configura-
tion capability, with more total input chan-
nels than any other PC/104 analog I/O
board. The board can be user-configured
in any of three ways:
Channels Format
32 32 single-ended
24 8 differential, 16 single-ended
16 16 differential
1-10 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model MicroCEM
Instruction Manual
748467-A
January 2002
c. Programmable Input Ranges
A programmable gain amplifier, programmable unipolar/bipolar range, and
programmable 5V/10V full-scale range
combine to give the ADIO board a total of
10 different possible analog input ranges.
All range settings are controlled in software for maximum flexibility.
Mode
Unipolar 10V 1 0-10V 0.153mV
Unipolar 5V 1 0-5V 0.076mV
Unipolar 5V 2 0-2.5V 0.038mV
Unipolar 5V 4 0-1.25V 0.019mV
Unipolar 5V 8 0-0.625V 0.0096mV
Bipolar 10V 1 ±10V 0.305mV
Bipolar 5V 1 ±5V 0.153mV
Bipolar 5V 2 ±2.5V 0.076mV
Bipolar 5V 4 ±1.25V 0.038mV
Bipolar 5V 8 ±0.625V 0.019mV
d. Enhanced Trigger and Sampling Con-
Full-
scale
trol Signals
The ADIO board has an extra A/D trigger
and sample control signals in the design.
Seven auxiliary digital I/O lines on the
analog I/O connector provide a sample/hold output signal, A/D trigger in and
out lines (to enable synchronization of
multiple boards) and external A/D clocking.
Gain
Input
Range
Resolution
e. Analog Outputs
The ADIO board contains 4 12-bit analog
outputs with autocalibration capability. Up
to 5mA of output current per channel can
be drawn from all channels simultane-
ously. Both unipolar and bipolar output
ranges are supported with jumper con-
figuration. And on power up, all outputs
are reset to 0V automatically.
Mode
Unipolar 10V 0-10V 2.44mV
Unipolar 5V 0-5V 1.22mV
Bipolar 10V ±10V 4.88mV
Bipolar 5V ±5V 2.44mV
f. FIFO and 16-Bit Bus Interface
An on-board 1024-byte FIFO enables the
ADIO board to work with Windows 95 and
NT by dramatically reducing the interrupt
overhead. Each interrupt transfers 256 2-
byte samples, or half the buffer, so the
interrupt rate is 1/256 the sample rate.
FIFO operation can be disabled at slow
sample rates, so there is no lag time be-
tween sampling and data availability. The
16-bit interface further reduces software
overhead by enabling all 16 A/D bits to be
read in a single instruction, instead of re-
quiring 2 8-bit read operations. The net
result of this streamlined design is that the
ADIO board supports gap-free A/D sam-
pling at rates up to 200,000 samples per
second, twice as fast as our previous
boards.
Full-
scale
Output
Range
Resolution
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-11
Instruction Manual
748467-A
January 2002
Model MicroCEM
+15V -15V
DC/DC
+15V
ADDR
CTRL
16-BIT DATA
AUTOCALIBRATION
CIRCUIT
1K X8
FIFO
MASTER
CONTROLLER
8255 CIRCUIT
16-BIT A/D
CONVERTER
X1,2,4,8
PROGRAMMABLE
GAIN AMP
12-BIT A/D
CONVERTERS
82C54
COUNTER/TIMER
10 MHZ
OSCILLATOR
INPUT MUX
HIGH CURRENT
DRIVE
ANALOG
INPUTS
0-31 SE
0-15 DI
ANALOG
OUTPUTS 0-3
TIMING AND
CONTROL SIGNALS
24 DIGITAL I/O
PC/104
BUS
Figure 1-9. ADIO Block Diagram
BUFFER
BUFFER
BUFFER
BUFFER
PORT A
PORT B
PORT CH
PORT CL
ACK/STROBE
1-12 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model MicroCEM
g. Specifications
Analog Inputs
Number of inputs ................... 32 single-ended, 16 differential, or 16 SE + 8 DI; user selectable
A/D resolution ........................ 16 bits (1/65,536 of full scale)
Bipolar ranges ....................... ±10V, ±5V, ±2.5V, ±1.25V, ±0.625V
Unipolar ranges ..................... 0-10V, 0-5V, 0-2.5V, 0-1.25V, 0-.625V,
Input bias current................... 100pA max
Overvoltage protection .......... ±35V on any analog input without damage
Nonlinearity............................ ±3LSB, no missing codes
Conversion rate ..................... 200,000 samples/sec.max
On-board FIFO ...................... 1K x 8(512 16-bit samples)
Calibration.............................. Automatic;values stored in EEPROM
Analog Outputs
Number of outputs ................. 4
D/A resolution ........................ 12 bits (1/4096 of full scale)
Output ranges........................ ±5, ±10, 0-5, 0-10
Output current........................ ±5mA max per channel
Settling time........................... 6µS max to 0.01%
Relative accuracy .................. ±1 LSB
Nonlinearity............................ ±1 LSB, monotonic
Reset ..................................... All channels reset to OV
Calibration.............................. Automatic; values stored in EEPROM
Digital I/O
Main I/O ................................. 24 programmable I/O
Input current........................... ±1µA max
Output current........................
Logic 0 ................................... 64mA max per line
Logic 1 ................................... -15mA max per line
Auxilary I/O ............................ 4 inputs, 4 outputs, optional use as trigger/control lines
Instruction Manual
748467-A
January 2002
Counter/Timers
A/D Pacer clock ..................... 32-bit down counter
(2 82C54 counters cascaded)
Clock source.......................... 10MHz on-board clock or external signal
General purpose.................... 16-bit down counter (1 82C54 counter)
General
Power supply ......................... +5VD±10%@200mA typ
Operating temperature .......... -25 to +85°C
Weight.................................... 3.4oz/96g
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-13
Instruction Manual
748467-A
January 2002
Model MicroCEM
1-7 PCMCIA ADAPTER
The PCMCIA adapter board (Figure 1-10)
supports Type I, II and III PCMCIA cards. The
board is in full compliance with Microsoft FFSII, PCMCIA V.2 and JEIDA 4.1 specifications.
The PCMCIA socket accepts The following
PCMCIA cards:
Type I Memory, Flash/SRAM/ROM
Type II Fax, Modem, LAN, Wireless LAN,
and SCSI
Type III ATA mass storage
a. Features
Dimensions
Compliant with the PC/104 standard
Compatible with AT PC/104 CPU modules
Functions on board
2 PCMCIA slots
Optional remote socket
PCMCIA features
Supports PCMCIA V.1.0 and V.2.0
Supports PCMCIA types I, II and III
Supports both I/O and Memory Card
Supports Hot insertion
Operating Systems
DOS and Windows and any other RTOS
that supports PCMCIA
Connectors
J1 : PCMCIA 2 slots connector
J3: PC/104 8 bit connector (XT compatible)
J4 : PC/104 16 bit extension (AT extension compatible).
Figure 1-10. PCMCIA Interface
b. Software
Software mappable memory windows and
one I/O window.
Jumperless interrupt steering from PC
Card to system.
Complete set of device drivers complying
with PCMCIA V2.1 /JEIDA V4.1, running
under MS-DOS or MS-WINDOWS:
• PCMCIA socket & card services drivers
• Flash File System
1-14 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model MicroCEM
1-8 MODEM
Instruction Manual
748467-A
January 2002
The PC/104 Modular Modem is a selfcontained modem module that provides the
flexibility to include modem functionality into
embedded system, with minimal engineering
resources. The PC/104 Modular Modem is full
featured including high-speed data and fax
transmission. The PC/104 Modular Modems
support both dial-up and 2-wire leased-line.
Figure 1-11 depicts the Modem.
a. Features
V.90, 56 kbps data (560PC/104)
V.34, 33.6 kbps data (336PC/104)
14.4 kbps fax
Voice playback and record
DTMF decode
-40oC to 85oC operation
3.775" x 3.550" x 0.568" (with modular
phone jack)
3.775" x 3.550" x 0.435" (without modular
phone jack)
8 bit PC/104 bus type
V.42 and MNP 2-4 error correction
V.42bis, and MNP-5 data compression
FCC Part 68 registered
FCC Part 15 compliant
2 wire leased-line and dial up support
Industry Canada CS-03 certified
Figure 1-11. Modem
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-15
Instruction Manual
748467-A
January 2002
1-9 FLASH DRIVE
Model MicroCEM
Figure 1-12. 128MB Flash Drive
a. Specifications
System Performance
All values quoted are typical at ambient temperature and nominal supply voltage unless otherwise
stated.
All performance timing assumes the controller is in the default (i.e., fastest) mode.
Start-up Time
Sleep to Write................................ 2.5 msec max.
Sleep To Read .............................. 2.5 msec max.
Reset to Ready.............................. 50 msec typical, 400 msec max.
Data Transfer Rate
to/from host............................ 16.0 MB/sec burst
Active to Sleep Delay .................... Programmable
Controller Overhead
Command to DRQ ................. <1.25 msec
Power Requirements
All values quoted are typical at ambient temperature and nominal supply voltage unless otherwise
stated.
DC Input Voltage
Commercial ................................... 3.3 V ± 5%, 5 V ± 10%
Industrial ........................................ 3.3 V ± 5%, 5 V ± 5%
1-16 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
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