Emerson Rosemount Analytical CAT 100 Instruction Manual

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Instruction Manual

748441-D May 2004

Model CAT 100

Continuous Analyzer Transmitter

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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

normal specifications. The following instructions MUST be adhered to 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.

to ensure they continue to operate within their

and integrated into your

• 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

•

Inform and educate your personnel in the proper installation, operation, and mainte-

marked on and supplied with the product.

nance 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 specified 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. Teflon® and Viton® are registered trademarks of E. I. duPont de Nemours and Co., Inc.

SNOOP® is a registered trademark of NUPRO Co.

Edition 04/2002 2nd Edition: 05/2004

Emerson Process Management Manufacturing GmbH & Co. OHG

Industriestrasse 1 D-63594 Hasselroth T +49(6055) 884-0 F +49(6055) 884-209

http://www.emersonprocess.com

Model CAT 100

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 Detector Methodologies.........................................................................................................1-2

a. Non-Dispersive Infrared (NDIR)......................................................................... .... .... ... ..1-2

b. Paramagnetic Oxygen Method...................................................................... .... .... ....... ..1-6

c. Electrochemical Oxygen Method................................................................ ... .... .... ....... ..1-7

d. Thermal Conductivity Method.........................................................................................1-9

1-4 Specifications.........................................................................................................................1-11

a. General ...........................................................................................................................1-11

b. CAT 100 Detector...........................................................................................................1-12

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2.0 INSTALLATION ....................................................................................................................2-1

2-1 Process and Calibration Gas Connection........................................................................ ... ..2-1

a. Gas Conditioning.............................................................................................................2-5

2-2 Installation..............................................................................................................................2-6

a. Location...........................................................................................................................2-6

b. Limitations.......................................................................................................................2-6

c. Gas Lines........................................................................................................................2-6

d. Services ..........................................................................................................................2-6

e. Mounting Options............................................................................................................2-6

f. Vent Lines.......................................................................................................................2-6

g. Electrical Connections ....................................................................................................2-7

2-3 Analytical Leak Check...........................................................................................................2-11

a. Flow Indicator Method.....................................................................................................2-11

b. Manometer Method.........................................................................................................2-12

3.0 OPERATION .........................................................................................................................3-1

3-1 Startup Procedure .................................................................................................................3-1

3-2 Touchpad...............................................................................................................................3-1

a. Overview.........................................................................................................................3-1

b. Elements.........................................................................................................................3-1

c. Actuator Tool...................................................................................................................3-2

d. Operation ........................................................................................................................3-2

e. Functions.........................................................................................................................3-3

f. FUNCTION Touchpad ....................................................................................................3-4

g. ENTER Touchpad...........................................................................................................3-5

h. INPUT-CONTROL Touchpads........................................................................................3-5

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Instruction Manual

748441-D April 2002

3-3 Entry of System Parameters..................................................................................................3-7

A. Pressure Correction........................................................................................................3-7

b. Cross Compensation ......................................................................................................3-7

c. Cross Compensation Calibration....................................................................................3-7

d. Hold.................................................................................................................................3-8

e. Automatic Calibration......................................................................................................3-8

f. Tolerance Check.............................................................................................................3-8

g. Display Off.......................................................................................................................3-9

h. Analog Signal Outputs...................................... .... .... ... .... .... .... ... .... .... .... ... .... .... .... .... .... .3-9

i. Flushing Period...............................................................................................................3-9

j. User Code..................................................................................................................... ..3-9

k. Response Time...............................................................................................................3-10

l. Offset Value....................................................................................................................3-10

m. Range Value ...................................................................................................................3-10

n. Reset...............................................................................................................................3-10

o. Program Version.............................................................................................................3-11

p. Serial Number.................................................................................................................3-11

q. Pump...............................................................................................................................3-11

3-4 Calibration..............................................................................................................................3-12

a. Zeroing............................................................................................................................3-12

b. Spanning.........................................................................................................................3-12

3-5 Manual Calibration.................................................................................................................3-13

a. Zeroing............................................................................................................................3-13

b. Spanning.........................................................................................................................3-13

3-6 Automatic Calibration (Option) ..............................................................................................3-15

a. Zeroing............................................................................................................................3-15

b. Combined Zeroing and Spanning...................................................................................3-15

3-7 Concentration Limits..............................................................................................................3-16

3-8 Measurement.........................................................................................................................3-17

3-9 Shut Down.............................................................................................................................3-18

3-10 Temperature Stabilization (option)........................................................................................3-19

a. Changing Temperature Settings.....................................................................................3-19

b. Controller Settings...........................................................................................................3-20

Model CAT 100

4.0 SERIAL INTERFACE OPTION.............................................................................................4-1

4-1 Overview................................................................................................................................4-1

4-2 Protocols........................................................................................................................... .....4-2

a. RS 232............................................................................................................................4-2

b. RS 485............................................................................................................................4-2

4-3 Setting I nterface Parameters.................................................................................................4-3

a. ON/OFF Status ...............................................................................................................4-3

b. Communication Parameters ...........................................................................................4-3

4-4 String Syntax .........................................................................................................................4-4

a. Status Strings..................................................................................................................4-5

b. Numerical Representations.............................................................................................4-6

c. Block Parity Check..........................................................................................................4-6

4-5 Instruction (Receive) Syntax.......... ............................................. ...........................................4-7

a. Instruction Listing............................................................................................................4-7

b. Response String Syntax .................................................................................................4-8

ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

5.0 MAINTENANCE AND SERVICE..........................................................................................5-1

5-1 Overview................................................................................................................................5-1

a. Operating Factors ...........................................................................................................5-1

b. Analyzer Replacement....................................................................................................5-1

c. Analyzer Repair...............................................................................................................5-1

5-2 Component Removal.............................................................................................................5-2

a. Analyzer Removal...........................................................................................................5-3

b. Analyzer Replacement....................................................................................................5-3

c. Power Supply Assembly Removal......................................................................... .........5-3

5-3 Analyzer Configuration and Adjustment................................................................................5-4

a. Component Layout..........................................................................................................5-4

b. Photometer Assembly.....................................................................................................5-9

c. Analyzer Rear Panel.......................................................................................................5-12

d. Thermal Conductivity Response Time............................................................................5-14

5-4 Maintenance..........................................................................................................................5-16

a. Routine and Preventive...................................................................................................5-16

b. Checking and Cleaning of the Analyzer..........................................................................5-16

c. Cleaning and Replacement of Photometric Components...............................................5-17

d. Light Source Replacement............................................................................. .................5-18

e. Removal of Analysis Cells ..............................................................................................5-19

f. Cleaning of Analysis Cells and Windows........................................................................5-20

g. Reinstalling Analysis Cells..............................................................................................5-20

h. Reinstalling Photometer Assembly.................................................................................5-20

i. Physical Zeroing..............................................................................................................5-20

j. Replacement of Electrochemical Oxygen Sensor ..........................................................5-21

k. Check of the Sensor........................................................................................................5-22

l. Removal of the Sensor ...................................................................................................5-23

m. Basic Calibration for the Oxygen Sensor........................................................................5-27

n. Sample Pump Maintenance............................................................................................5-27

o. Replacing the EPROM....................................................................................................5-28

5-5 Analyzer Service....................................................................................................................5-29

a. Test Points for BKS PC Board........................................................................................5-29

b. Test Points for OXS PC Board........................................................................................5-35

c. Power Supply..................................................................................................................5-37

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6.0 TROUBLESHOOTING..........................................................................................................6-1

6-1 Error Messages ................................................................................................................... ..6-1

6-2 Troubleshooting Leaks..........................................................................................................6-6

7.0 RETURN OF MATERIAL................................................................................... .................7-1

7-1 Return Of Material.................................................................................................................7-1

7-2 Customer Service..................................................................................................................7-1

7-3 Training..................................................................................................................................7-1

8.0 INDEX....................................................................................................................................8-1

Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii

Instruction Manual

748441-D April 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. Electrochemical Oxygen Sensor............................................................................ 1-7

Figure 1-6. Reaction of Galvanic Cell ....................................................................... .... .... .... ...1-8

Figure 1-7. Thermal Conductivity Sensor................................................................................. 1-9

Figure 1-8. Response Time vs Flow Rate Dependence........................................................1-10

Figure 2-1. Gas Connections........................................... .... .... ... .... .... .... ... .... .... .... ... .... .... .... ...2-2

Figure 2-2. Piping Diagram (Two channel series).................................................. .... ... .... .... ...2-3

Figure 2-3. CAT 100 Outline and Mounting Di mensions......................................................... 2-4

Figure 2-4. Increased Safety Junct ion Box Terminals............................ .... ... .... .... .... ... .... .... .2-10

Figure 2-5. Leak check - Flow Indicator Method....................................................................2-11

Figure 2-6. Leak Check - Manometer Method....................................................................... 2-12

Figure 3-1. CAT 100 Touchpad........................................ .... ... .... .... .... .... .... ... .... .... .... ... .... .... ...3-1

Figure 3-2. Touchpad Actuator Tool PN 42715575................................................................. 3-2

Figure 3-3. Storing The Actuator Tool......................................................................................3-2

Figure 3-4. Touchpad Operation..............................................................................................3-3

Figure 3-5. CAT 100 Analyzer Touchpad Function Identification............................................3-3

Figure 3-6. CAT 100 Touchpad Functions.......................................... .... ... .... .... .... .... ... .... .... ...3-4

Figure 3-7. Analyzer Operating Function Matrix..................................................................... 3-6

Figure 3-8. Temperature Controller............................................................... ........................3-19

Figure 5-1. CAT 100 Enclosure Assembly............................................................................ ...5-2

Figure 5-2. Analyzer Component Layout (Infrared Channel / Oxygen Measurement,

Combined) .............................................................................................................5-5

Figure 5-3. Analyzer Component Layout (1 Channel Oxygen Measurement,

Electrochemical)....................................................................................................5-6

Figure 5-4. Analyzer Component Layout (Paramagnetic Oxygen Measurement / Thermal

Conductivity, Combined)........................................................................................5-7

Figure 5-5. Analyzer Component Layout (Infrared Channel / Thermal Conductivity,

Combined) .............................................................................................................5-8

Figure 5-6. Photometer Assembly with Pyroelectrical Detector.............................................5-10

Figure 5-7. Photometer Assembly with Gas Detector............................................................ 5-11

Figure 5-8. Analyzer Rear Panel Layout................................................................................ 5-12

Figure 5-9. Pin Assignments (View Looking At Rear Panel)..................................................5-13

Figure 5-10. TC Sensor Short Response Time Setting (Standard).........................................5-15

Figure 5-11. TC Sensor Long Response Time Setting............................................................5-15

Figure 5-12. Analyzer Photometer Assembly ( 2 Channel Infrared Analyzer, Viewed From

Front Panel Side).......................................................... .......................................5-17

Figure 5-13. Photometer Assembly..........................................................................................5-19

Figure 5-14. OXS PCB Measuring Points................................................... ............................5-22

Figure 5-15. Oxygen Sensor without Infrared Channel...........................................................5-23

Figure 5-16. OXS PCB Connector P2.....................................................................................5-24

Figure 5-17. Oxygen Sensor Support (Oxygen Measurement Without Infrared Channel)..... 5-24

Figure 5-18. Oxygen Sensor with Infrared Channel................................................................5-25

Figure 5-19. OXS PCB Location of Measuring Points and Voltage Adjustment..................... 5-27

Figure 5-20. BKS PCB Location of EPROM and Battery Buffer Jumper (J7)......................... 5-28

Figure 5-21. BKS PCB Test Points........................................................................................5-29

Figure 5-22. BKS PCB Plug Locations....................................................................................5-33

Figure 5-23. BKS PCB Jumper Locations.............................................................................. .5-34

Figure 5-24. OXS PCB Test Points.........................................................................................5-35

Figure 5-25. OXS PCB Plug Locations................................................................................... 5-36

Figure 5-26. Power Supply Connections.................................................................................5-37

Model CAT 100

LIST OF ILLUSTRATIONS

iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

Table 2-1. Analog Output Terminal Assignments..................................... .... .... ....... .... .... .... ...2-7

Table 2-2. Digital Output Terminal Assignments.................................................................... 2-8

Table 2-3. Optional Status Signals Terminal Assignments.....................................................2-8

Table 2-4. Optional Cross Compensation Analog Inputs................... .....................................2-8

Table 2-5. Optional RS232/485 Terminal Assignments.......................................................... 2-9

Table 2-6. Power Connections Terminal Assignments...........................................................2-9

LIST OF DRAWINGS

659921 Assembly Drawing, CAT 100 660198 Wiring Diagram, CAT 100 660210 Installation Drawing, CAT 100 660371 Diagram, Power Input and Ground Circuits

LIST OF TABLES

(Located In Rear Of Manual)

Instruction Manual

748441-D

April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Contents v

Instruction Manual

748441-D April 2002

Model CAT 100

vi Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

Model CAT 100

PREFACE

The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the CAT 100 .

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.

748441-D

April 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

748441-D April 2002

Model CAT 100

INTENDED USE STATEMENT

The Rosemount Analytical 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 p ower.

DANGER.

POSSIBLE EXPLOSION HAZARD

Do not operate without dome and 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 CAT 100

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 con-

nections for leakage.

Keep all tube fittings tight to avoid leaks. See Sections 2-3 (page 2-11) and 6-2 (page 5-6) for leak check information.

WARNING.

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April 2002

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 a Rosemount Analytical Service office for service or repair to ensure that safety features are maintained.

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3

Instruction Manual

748441-D April 2002

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.

CAUTION.

HEAVY WEIGHT

Use two persons or a suitable lifting device to move or carry the instrument.

Model CAT 100

P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

748441-D

Model CAT 100

April 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 secure d 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 suck back can occur when an empty cylinder is attached to a pressurized system.

7. No part of cylinder should be su bjec ted to a temperat ure hig her than 125 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.

F (52 °C). A flame should

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5

Instruction Manual

748441-D April 2002

Model CAT 100

DOCUMENTATION

The following CAT 100 instruction m ateria ls are av ailab le . Contact Customer Service Center or the local representative to order.

748441 Instruction Manual (this document)

COMPLIANCES

This product may carry approvals from several certifying agencies. The certification marks appear on the product name-rating plate.

Area Classifications:

USA

Class I Zone 1

AEx d e m IIB + H

Canada

Ex d e m IIB + H

European Union

ATEX, Category 2, Zone 1, IIB + H

USA/Canada

Certified by Canadian Standards Association, an OSHA Nationally Recognized Testing Laboratory (NRTL) for USA and Canada.

European Union

Conforms with the provisions of the EMC Directive 89/336/EEC, Low Voltage Directive 73/23/EEC, Potentially Explosive Atmospheres Directive 94/9/EC, including amendments by the CE marking Directive 93/68/EEC.

EC type Examination Certificate, LCIE 00 ATEX 6009 X. Rosemount Analytical has satisfied all obligations from the European Leg-

islation to harmonize the product requirements in Europe.

Australia/New Zealand

Conforms with Electromagnetic Compatibility – Generic Emission standard and AS/NZS 4251.1 – 1994 Pa rt 1 – Residential, commercial, and light industrial.

Complies with the NAMUR RECOMMENDATION, Electromagnetic Compatibility (EMC) issue 1998.

0081

EEx d e m II B (+H2) T4 LCIE 00 ATEX 6009 X

II 2 G

NAMUR

P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

DESCRIPTION AND SPECIFICATIONS

Instruction Manual

748441-D

April 2002

SECTION 1

1-1 OVERVIEW

This manual describes the CAT 100 Continuous Analyzer Transmitter.

The CAT 100 is a 1 or 2 channel Continuous Gas Analyzer with FOUNDATION Fieldbus communications. Its Class I, Zone I (IIB) + H approved enclosure makes it suitable for installation in hazardous environments. The field mountable housing design allows the CAT 100 to be mounted close to the process instead of in a remote shelter. This feature greatly reduces installation and utility costs while improving process efficien cy.

The CAT 100 can continuously measure 1 or

Carbon Monoxide (CO) Carbon Dioxide (CO Hexane (CH equiv.) (C Hydrogen (H Ethylene (C

) Helium (He) Argon (Ar)

) Propane (C3H8) Butane (C4H10)

2H4

6H14

Some standard industry applications include:

Petrochemical Refinery

•

Light Naphtha Isomerization

, CO and CO2 in make-up Hydrogen

Gas to Combined Feed H

in Scrubber Off Gas to Refinery Fuel

Gas Header

•

Catalytic Reforming

in Recycle Gas from Product Separa-

tor H

in Net Gas from Net Gas Knockout

Drum H

in CCR Nitrogen Header

in Surge Hopper Vent

•

Fluidized Catalytic Cracking

CO and O

Monitoring of Fluidized Cata-

lytic Cracking Regenerator Gas

•

Sulfur Recovery Units

2 components in a single analyzer using a combination of Non Dispersive Infrared (NDIR), Paramagnetic Oxygen, Thermal Conductivity, and Electrochemical sensors. The CAT 100 also features an optional customized sample-handling module.

1-2 TYPICAL APPLICATIONS

The CAT 100 Continuous Analyzer Transmitter supports a variety of industry applications, drawing on more than 40 years of development and process expertise in sensors, digital signal processing and software technologies. The CAT 100 can satisfy the most demanding single or multi-component analysis requirements. More than 60 gas components can be measured including:

) Methane (CH4)

) Water Vapor (H2O) Oxygen (O2)

Propylene in Feed to Sulfur Recovery Plant

Petrochemical Complex

Ethylene in Primary and Secondary DeMethanizer Overhead

in Ethane-Ethylene Splitter

Propylene in Splitter Bottoms

Ammonia and Urea

, CO and CO2 in Synthesis Gas

Utilities

in Cooling Gas in Turbine Generators

Continuous Emission Monitoring Systems (CEMS)

Metals

in Endothermic Furnace

All Applications

Continuous Emission Monitoring Systems (CEMS)

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1

Instruction Manual

748441-D April 2002

Model CAT 100

1-3 DETECTOR METHODOLOGIES

The CAT 100 can employ up to two of four different measuring methods depending on the configuration chosen. The methods are: NDIR, Paramagnetic O

, Electrochemical O2,

and Thermal Conductivity.

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 measured. The gas-specific wavelengths of the absorption bands characterize the type of gas while the strength of the absorption gives a measure of the concentration 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 detector signal thus alternates between concentration dependent and conce nt rat ion independent values. The difference between the two is a reliable measure of the concentration of the absorbing gas component.

Depending on the gas being measured and its concentration, one of two different measuring methods may be used as follows:

Interference Filter Correlation (IFC)

With the IFC method the analysis cell is alternately illuminated with filtered infrared concentrated in one of two spectrally separated wavelength ranges. One of these two wavelength bands is chosen to coincide with an absorption band of the sample gas and the other is chosen such that none of the gas constituents expected to be encountered in practice absorbs anywhere within the band.

The spectral transmittance curves of the interference filters used in the CAT 100 analyzer and the spectral absorption of the gases CO and CO

are shown in

Figure 1-1 (page 1-3). It can be seen that the absorption bands of these gases each coincide with the pas s bands of one of the interference filters. The forth interference filter, used for generating a reference signal, has its pass band in a spectral region where none of these gases absorb. Most of the other gases of interest also do not absorb within the pass band of this reference filter.

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.

1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

Figure 1-1. Absorption Bands of Sample Gas and Transmittance of Interference Filters

Transmittance (%)

CO2 CO

bsorption Band

Transmittance (%)

0 15 30 54 60 75 90

HC CO

0 18 36 54 72 90

3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600

Reference

Wave Length (nm)

Instruction Manual

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April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3

Instruction Manual

748441-D April 2002

Opto-Pneumatic Method

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 compen sation chamber which are connected by a flow channel in which a Microflow filament sensor is mounted. This is shown 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

bsorption chamber

Flow channel with Microflow sensor

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 absorption chamber is heated, expands and some of it passes through the flow channel 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 reference side. Absorption chamber gas becomes 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 electrical pulses which are processed into the corresponding analyzer output.

Window

CaF

Figure 1-2. Opto-Pneumatic Gas Detect or

Model CAT 100

Compensation chamber

1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

Instruction Manual

748441-D

April 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

depending on the application and ne ed 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 directly in the appropriate physical concentration units such as percent v olume, ppm, mg/Nm

, etc. This is shown in

Figure 1-3 (page 1-5).

MOTOR

Light Source

Chopper Blade

Duplex Filter Disc

Analysis Cell

(measuring side)

Analysis Cell

(reference side)

dapter Cell

(high measuring range)

nalysis Cell

(undivided)

Filter Cell Preamplifier

Filter Cell

Pyroelectric Detector (solid-state detector)

Gas Detecto

Preamplifie

Chopper Blade

Figure 1-3. Overall NDIR Method

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5

Instruction Manual

748441-D April 2002

Model CAT100

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 diamag-

netic or repelled by a magnet. A small mirror that reflects a light beam

coming from a light source to a photo detector, 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

Light

Source

Photo detecto

Display

magnetic field strength. The oxygen molecules thus exert different forces on the two suspended nitrogen filled quartz spheres, producing a torque which causes the mirror to rotate away from its equilibrium position.

The rotated mirror deflects the incident light onto the photo detector creating an 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 restoring torque to return the quartz bar to its equilibrium position is a direct measure of the O

The complete paramagnetic analysis cell consists of an analysis chamber, permanent magnet, processing electronics, and a temperature sensor. The temperature sensor is used to control a heat exchanger to warm the measu ring gas to about 55 °C. Refer to Figure 1-4 (page 1-

6).

Permanent Magnet

Platinum Wire

Mirror

mplifier

Quartz Sphere(s)

Wire Loop

Figure 1-4. Paramagnetic Oxygen Analysis

concentration in the sample gas.

1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

Instruction Manual

748441-D

April 2002

c. Electrochemical Oxygen Method

The electrochemical method of det ermining oxygen concentration is based on the galvanic cell principle shown in Figure 1-6 (page 1-8).

The electrochemical oxygen sensor (Figure 1-5, page 1-7) 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 (t

) of the sensor is dependent on the

thickness of the Teflon membrane.

The electric current between the electrodes is proportional to the O

concentra-

tion in the sample gas being measured. The resultant signal is measured as a voltage across the resistor and thermistor, the latter of which is use d for temperature compensation. A change in the output voltage (mV) represents oxygen concentration.

NOTE

The electrochemical O

cell requires a

minimum internal consumption of oxygen. Sample gases with an oxygen concentration of less than 0.1 % could result in a reversible detuning of sensitivity and the output will become unstable. The recommended practice is to purge the cell with conditioned ambient air between periods of measurement. If the oxygen concentration is below 0.1 % for several hours or days, the cell must be regenerated for about one day with ambient air. Temporary flushing with nitrogen (N

) for less than

one hour (analyzer zeroing) will have no effect on the sensitivity or stability.

Lead Wire (Anode)

Lead Wire (Cathode)

Anode (Lead)

O-Ring

Black

Red

Resistor

Plastic Disc

Plastic Disk

Thermistor

cid Electrolyte

Sponge Disc

Cathode (Gold Film)

Teflon Membrane

Figure 1-5. Electrochemical Oxygen Sensor

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7

Instruction Manual

(

)

(

)

748441-D April 2002

Red

Thermistor (5

(-) (+)

Gold Lead

Cathode (2) Anode (1)

O2 + 4 H + 4 e → 2 H2O2 Pb + 2 H

Summary reaction O

V out

Electrolyte (3)

(ph 6)

+ 2 Pb → 2 PbO

Black

Resistor (6

O → 2PbO + 4 H + 4 e

Figure 1-6. Reaction of Galvanic Cell

Model CAT100

1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

d. Thermal Conductivity Method

Instruction Manual

748441-D May 2004

To measure gases like Hydrogen (H Helium (He), the measurement method of thermal

conductivity (TC) will be used.

Sensor Design

The sensor consists of four small PT 100 resistors arranged in a Wheatstone Bridge which is mounted into a block made of either aluminum, stainless steel or Hastelloy, depending on the application (e.g. stainless steel / Hastelloy for corrosive gases). The block is thermostat controlled to suppress influence of external temperature change.

Analysis Cell

Both the volume of the block and the mass of the resistors have been minimized on order to obtain short response time. The block contains two gas paths for sample and reference gas, whereat the reference gas path is closed for standard applications. Always two sensors are located in the sample and the reference gas path. The resistors are full glass packaged to withstand aggressive gases.

Figure 1-7. Thermal Conductivity Sensor

), Argon (Ar) or

The material in contact with the gases are glass, Gold, Aluminum, stainless steel and Hastelloy, so a high resistance against corrosion by aggressive gases is provided by this cell.

Measurement Method

The entire measurement cell is thermostat controlled to a temperature of up to 75 °C. The four sensors are electrically heated to a high er temperature and the signal of the Wheatstone Bridge is monitored. Depending on the thermal conductivity of the gases that pass the cell, the temperature of the sensors in contact with the gas changes and thus their electrical resistance. This changes the output signal of the Wheatstone Bridge and electronic circuitry processes this signal to obtain standardized signal amplitudes, and transmits these to both an indicator instrument and to the signal output connector.

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-9

Instruction Manual

748441-D May 2004

Model CAT 100

1-10 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

1-4 SPECIFICATIONS

a. General

Power ............................................Universal Power Supply 90-264 VAC, 50-60 Hz, ±10% 180 Watts

Channels (Detectors)/Number....... NDIR, PMD (PO

Mounting........................................ 4” or 6” Pipe, Rack, or Wall Mount

Area Classification......................... See Compliances page P-6

Corrosion Protection Option.......... Instrument grade air is required. Consult factory for requirements

Ambient Range.............................. Temperature (Standard): +5 °C to +45 °C (+41° to 113 °F)

Temperature (Optional): -30 °C to +50 °C (-34° to 122 °F) Relative Humidity: 5 % to 95 %

Inputs/Outputs...............................Digital: RS 232/ RS 485 serial data or

Analog Current Outputs: Up to 2 isolated 4-20 mA, common

Analog Digital Outputs: Up to 8, 5-30 VDC, max current 30 mA Analog Current/Voltage Input: Up to 3 (Option for TC electronic

Relay Outputs: Up to 3 “non-voltage carrying contacts”, max 30 V,

Instrument Weight......................... 120 to 150 lbs. (55-70 kg)

Instruction Manual

748441-D

April 2002

Maximum at Start Up. Up to 380 Watts with optional case heater.

), E02, TC. Up to two in one analyzer.

FOUNDATION Fieldbus

ground, burden: R

cross compensation) 0(2) - 10 V, 0(4) - 20 mA, 0(0.2) - 1 V

1 A, 30 W

< 500 ohms

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-11

Instruction Manual

748441-D April 2002

b. CAT 100 Detector

Model CAT100

Detection Limit

2,3

Linearity Zero Drift Span Drift Repeatability Response Time

2,3

NDIR

≤1% ≤1% ≤1% ≤2%

Paramagnetic

Electrochemical

≤1% ≤1% ≤1% ≤1%

≤

2%/week

≤

2%/week

≤

2%/week

≤1%/week ≤1%/week ≤1%/week ≤2%/week

≤1% ≤1% ≤1% ≤1%

5 s ≤ t90 ≤7 s

<5-6 s 12s

Thermal

Conductivity 1

≤

2%/week

3s ≤ t90 ≤ 20s 4 Sample Flow Rate .2-1.5 l/min .2-1.0 l/min .2-1.5 l/min .2-1.5 l/min Sample Pressure

≤

1,500 hPa abs

Atm

≤

1,500 hPa abs

≤

1,500 hPa abs Influence of Pressure Standard 5 Pres. Comp. Opt.

≤

0.1%/hPa

≤0.01%/hPa

≤

0.1%/hPa

≤0.01%/hPa

≤

0.1%/hPa

≤0.01%/hPa

≤

0.1%/hPa

≤0.01%/hPa Influence of Temperature On Zero On Span On Span

2 2,6

Sensor Materials in Contact with Sample

Warm-up Time

≤

≤5%

≤

Anodized Alum,

Stainless Steel

(gold coated),

BaF

, CaF2

15 to 50 Min

≤

≤1%

≤

Stainless Steel,

Platinum, Glass,

PTFE, PVDF,

FPM, Epoxy

resin (Solvent

resistant: no FPM, no epoxy but Nickel, Kal-

rez)

50 Min 15 to 50 Min 50 Min

≤

≤2%

≤

Aluminum,

Stainless Steel,

FPM, Gold &

ABS,

Teflon

Stainless Steel/

Hastelloy/Glass

≤

≤5%

≤

Glass;

Thermostatically controlled cell 55 °C.

Related to full scale, per 10 K.

At constant pressure and temperature.

Dependent on sensor.

Related to measuring valu e.

With optional temperature stabilization.

Starting from 20° C to +5 °C or +40 °C.

1-12 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

Instruction Manual

748441-D May 2004

SECTION 2

INSTALLATION

DANGER.

POSSIBLE EXPLOSION HAZARD

Do not open while energized. Do not operate without dome and covers secure. Installation of this device must be made in accordance with all applicable national and/or local codes. See specific references on installation drawing located in the rear of this manual.

DANGER.

ELECTRICAL SHOCK HAZARD

Installation and servicing of this device requires access to components that may present electrical shock and/or mechanical hazards. Refer installation and servicing to qualified service personnel.

CAUTION.

HIGH PRESSURE GAS CYLINDERS

2-1 PROCESS AND CALIBRATION GAS CON-

NECTION

Besides sample gas, the CAT 100 requires other gases for operation. In most cases, one or more Calibration Standards mus t be provided. These should be cylinders of gas which closely resemble the expected sample, both in

species and concentrations. These calibration gases are normally introduced into the system as an input to the Sample Conditioning Plate Option or sample conditioning may be provided by others.

Each gas cylinder should be equipped with a clean, hydrocarbon free two-stage pressure regulator with indicating gauges of approximately 0 to 3000 psig (0 to 207 bar) for cylinder pressure and 0 to 100 psig (0 to 6.7 bar) for delivery pressure. Pressure regulators should have a metallic as opposed to elastomeric diaphragm, and provide for ¼ inch compression fitting outlet and should be LOX clean.

NOTE

All connections specified in the Installation Drawing, in conjunction with the Application Data Sheet, should be made.

For single channel and dual channel CAT 100 analyzers being plumbed in series, connection 1 is the gas inlet and connection 2 is the g as outlet for both channels. Dual channel analyzers with parallel tubing use gas inlets and outlets noted in Figure 2-1

When ONE optional auto calibration solenoid valve block is installed, the sample gas is introduced to connection 9 instead of connection 1. In this case, the outlet at connection 5 is used.

When parallel tubing and TWO auto calibration valve blocks are supplied, gas inlet 3 and gas outlet 4 are used for the second channel. Zero gas 1 and span gas 1 are used for channel 1 (valve block 1) while zero gas 2 and span gas 2 are used for channel 2 (valve block 2) (see Figure 2-1

(page 2-2).

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 2-1

Instruction Manual

748441-D May 2004

Model CAT 100

An external flow meter may be used (if no internal is available) to adjust the flow rate. In

nel series analyzer is show in Figure 2-2

(page 2-3). hazardous areas this must be done in accordance with the legislation. The flow must be adjusted so that calibration gases and sample gas have the same rate. The auto calibration solenoid valve option is only available with a two-channel analyzer with series connection.

Sample pump and solenoid value options are

available with parallel channels depending on

space only. For parallel channels, an external

optional sample handling plate as shown in

Figure 2-3 (page 2-4) may be required to pro-

vide pumping, valving and throttling capabiliAn example of a typical gas connection ar-

ties as necessitated by the application. rangement for a single channel or dual chan-

1 2 3 4

Flow Meter*

(option)

567

8 9 10 11

Bottom View

Single or dual channel (Ch) in series:

1 – Gas Inlet (Ch1) 2 – Gas Outlet (Ch1)

Dual channel in parallel:

1 – Gas Inlet (Ch1) 2 – Gas Outlet (Ch1) 3 – Gas Inlet (Ch2) 4 – Gas Outlet (Ch2)

Single or dual channel in series including one auto calibration valve block:

5 – Outlet (Span/Zero/Sample)* 6 – Span Gas 1 Inlet 7 – Span Gas 2 Inlet 8 – Zero Gas Inlet 9 – Sample Gas Inlet

Dual channel in parallel including two auto calibration valve blocks:

1 – Gas Inlet (Ch1) 2 – Gas Outlet (Ch1) 3 – Gas Inlet (Ch2) 4 – Gas Outlet (Ch2) 6 – Span Gas 1 Inlet 7 – Span Gas 2 Inlet 8 – Zero Gas 1 Inlet 10 – Zero Gas 2 Inlet Option Purge of the CAT housing: 11 – Purge Gas Inlet

* Standard: Outlet = Gas outlet ; Valve block outlet is connected to internal BINOS gas inlet; Option: Valve block outlet maybe used as outlet for external sample handling (special solution: consult factory)

Figure 2-1. Gas Connections

2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

Span gas 1

Span gas 2

Sample gas

Zero gas

Solenoid Valve

Block

(option)

Channel 2

(option)

Gas Sampling Pump

Throttle and Safety Filter

Channel 1

(option)

Flow Meter

(option)

Figure 2-2. Piping Diagram (Two channel series)

Instruction Manual

748441-D

April 2002

Gas Outlet

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3

Instruction Manual

[

]

[

]

[

]

[

]

[

748441-D April 2002

16.00

27.00

685.8]

14.25 362]

25.50

647.7]

.62

[15.7]

1.25

[31.8]

2.25

[57.2]

Figure 2-3. CAT 100 Outline and Mounting Dimensions

406.4

13.00

330.2

MOUNTING HOLE .625 [15.88] DIA 4 PLC’S

2.00

50.8

1.00

25.4

D. SAMPLE HANDLING PLATE OPTION. SIZE AND

ARRANGEMENT SUBJECT TO APPLICATION.

C. ELEVEN GAS CONNECTION PORTS (IF REQUIRED

FOR APPLICATION, FLAME ARRESTOR(S) INSTALLED). SEE FIGURE 2-1.

B. ANALOG AND DIGITAL I/O PORTS (M16 x 1.5).

. INCREASED SAFETY JUNCTION BOX.

Note: The Increased Safety Junction Box must be protected by fuse supply which has a breaking capacity adjusted to the short circuit of the equipment.

2.50

[63.5]

DIMENSIONS

INCH

Model CAT100

3.00

76.2]

2.90

[73.7]

2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

Instruction Manual

748441-D

April 2002

a. Gas Conditioning

If the CAT 100 is not supplied with the optional Sample Handling Plate, care must be taken to ensure that the sample gas is properly conditioned for successful operation of the various detectors.

All gases must be supplied to the analyzer as conditioned gases! When the system is used with corrosive gases, it must be verified that there are no gas components which may damage the gas path components.

The gas conditioning must meet the following conditions:

•

Free of condensable constituents

•

Free of dust above 2 µm

•

Free of aggressive constituents which may damage the gas paths

When analyzing vapors, the dew point of the sample gas must be at least 10 °C below the ambient temperature in order to avoid the precipitation of condensate in the gas paths.

An optional barometric pressure compensation feature can be supplied for th e CAT 100. This requires a pressure sensor with a range of 800 – 1,100 hPa. The concentration values computer by the detectors will then be corrected to eliminate erroneous measurements due to changes in barometric pressure.

The gas flow rate must be in the range of

0.2 l/min to a maximum of 1.5 l/min. A constant flow rate of 1 l/min is recommended.

NOTE

The maximum gas flow rate for paramagnetic oxygen detectors is 1. 0 l / mi n !

• Temperature and pressure in ac-

cordance with the specifications

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5

Instruction Manual

748441-D April 2002

Model CAT100

2-2 INSTALLATION

CAUTION.

Do not operate or service this instrument before reading and understanding this instruction manual and receiving appropriate training.

WARNING

ELECTRICAL SHOCK HAZARD

POSSIBLE EXPLOSION HAZARD

Do not open while energized. Do not operate without dome and covers secure. Installation requires access to live parts which can cause death or serious injury.

CAUTION.

HIGH PRESSURE GAS CYLINDERS

Refer to the installation drawing supplied with the application data package.

a. Location

The CAT 100 is designed to be installed in unsheltered environmental locations. It is recommended that the analyzer be located out of direct sunlight to the extent possible.

The CAT 100 should be installed as near as possible to the sample point, in order to avoid low response time caused by long sample gas lines.

b. Limitations

See Specification, Section 1-4 (page 1-

11).

c. Gas Lines

For external gas lines, the use of all new tubing throughout is strongly recommended. The preferred type is new, refrigeration grade copper tubing, sealed at the ends. Generally, stainless steel tubing is less desirable as it contains hydrocarbon contaminants introduced through cleaning. Pre-cleaned and rins ed st ain less steel tubing is available from various supply houses, and is recommended if stainless steel is desired.

d. Services

All input power, AC or DC as well as input and output digital and analog signals connect through the Safety Junction Box located above the CAT 100 dome.

Power Cable

AC Operation: 16 gauge, minimum . DC Operation: 12 gauge, minimum.

e. Mounting Options

The CAT 100 can be mounted to either 4½ or 6-¼ inch diameter pipe stands. Alternately, the analyzer can be wall or floor mounted.

Although the CAT 100 is enclosed in an explosion proof and environmentally sealed enclosure (NEMA 4X, IP 55), it should be protected from direct sunlight. In areas subjected to harsh winter climates, protection should be provided from rain and snow. A corrugated awning or other suitable means can be provided to meet these conditions.

See drawing 660210 located in the rear of this manual for typical pipe mounting method. Note that the mounting stand is an option.

f. Vent Lines

Connect all vent lines (thes e are specified on the Application Data Sheet) to an ap-

2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

Instruction Manual

748441-D

April 2002

propriate header. The header should have a means of being purged when venting dangerous gases. Insure that there is no backpressure in the vent system as this will cause variations in the repeatability of

through the Increased Safety Junction Box. Cable length for these signals should not exceed 3,000 feet (914 meters), to avoid excessive capacitance and corresponding signal distortion.

the system.

The following connections are made

g. Electrical Connections

through the Increased Safety Junction Box:

NOTES

•

1) The enclosure is a NEMA 4X/ IP 55. All entry locations must be sealed.

2) North American area classification – Class I Zone 1, Group IIB +H

T4.

CENELEC Category 2 – Zone 1, Group IIB +H

T4.

Electrical Power

•

2 Analog Outputs

•

Optional 3 Analog Inputs (for TC cross compensation)

• 8 Digital Outputs

3) Readily accessible main power disconnect to be supplied by customer.

4) Electrical installation to be in ac-

• RS 232/RS 485 or Optional FIELDBUS

•

Optional 3 Relay Outputs

cordance with National Electrical Code. (ANSI/NFPA 70) and or other applicable national or local codes.

Connect all required signal cables to the Increased Safety Junction Box. The cable entry locations are indicated on

Connections must be made as follows:

USA: ½” Rigid Metal Conduit European Union: Certified Glands Canada: Either

the inside cover of the junction box. The actual electrical connections will be specified in the Application Data package. All connections are not necessary for every application.

The Increased Safety Junction Box must be protected by fuse supply which has a breaking capacity ad-

All analog/digital inputs and analog/digital/serial outputs are made

justed to the short circuit of the equipment.

Terminal Description

Top 16 (C-wht) VDC Gnd Top 17 (C-wht/blk) 0 (2) – 10 VDC [option 0 (0.2) – 1 VDC], Channel 1 Top 18 (C-wht/brn)

0 (4) – 20 mA, Channel 1 (R

≤ 500 Ω)

Top 19 (C-wht/red) 0 (2) – 10 VDC [option 0 (0.2) – 1 VDC], Channel 2 Top 20 (C-wht/org)

0 (4) – 20 mA, Channel 2 (R

≤ 500 Ω)

Bottom 16 (C-wht/yel) mA return (Gnd) Bottom 17 (C-wht/grn) mA return (Gnd) Bottom 18 (C-wht/blu) mA return (Gnd) Bottom 19 (C-wht/vio) mA return (Gnd)

Table 2-1. Analog Output Terminal Assignments

NOTE

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7

Instruction Manual

748441-D April 2002

Terminal Description

Bottom 1 (C-blk) High limit reached, channel 2 Bottom 2 (C-brn) Low limit reached, chan nel 2 Bottom 3 (C-red) High limit reached, channel 1 Bottom 4 (C-org) Low limit reached, chan nel 1 Bottom 5 (C-yel) Gnd Bottom 6 (C-grn) Valve control, span gas 2 Bottom 7 (C-blu) Valve control span gas 1 Bottom 8 (C-vio) Valve control, zero gas Bottom 9 (C-gry) Valve control, sample gas

Note: The loading of the open collector digital outputs is a maximum of 30 VDC and 30 mA.

Terminal Description

Bottom 10 (C-wht/gry) OK/Failure (open/closed) Bottom 11 (C-blk/red) OK/Failure (closed/open) Bottom 12 (C-blk/org) Measure/Calibration (open/closed) Bottom 13 (C-blk/yel) Measure/Calibration (closed/open) Bottom 14 (C-blk/grn) OK/Failure (common) Bottom 15 (C-blk/blu) Measure/Calibration (common) Bottom 20 (D-blk/yel) Pump Off/On (open/closed) Bottom 21 (D-blk/blu) Pump Off/On (closed/open) Top 21 (D-blk/grn) Pump Off/On (common)

Note: Non-voltage carrying contacts, maximum 30 V, 1 A, 30 W.

Table 2-3. Optional Relay Outputs (Status Signals) Terminal Assignments

Terminal Description

Top 1 (D-blk) Interfering gas 1 Top 2 (D-brn) Interfering gas 1 Top 3 (D-red) Interfering gas 2 Top 4 (D-org) Interfering gas 2 Top 5 (D-yel) Interfering gas 3 Top 6 (D-grn) Interfering gas 3 (Gnd)

Table 2-4. Optional Analog Inputs for TCD Cross Compensation

Model CAT100

Table 2-2. Digital Output Terminal Assignments

2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

Terminal Signal Terminal Signal

Top 7 (D-blu) Gnd Top 11 (D-wht/blk) Gnd Top 8 (D-vio) RxD Top 12 (D-wht/brn) RxD Top 9 (D-gry) TxD Top 13 (D-wht/red) RxD + Top 10 (D-wht) Gnd Top 14 (D-wht/org) TxD Top 15 (D-wht/yel) TxD +

Table 2-7. Foundation Fieldbus Terminal Assignments (option)

Connect AC power through a 10 A circuit breaker that is to be located close to the CAT 100. The circuit breaker will provide over current protection as well as a means of disconnecting the power.

Instruction Manual

748441-D

April 2002

RS 232 RS 485

Table 2-5. Optional RS232/485 Terminal Assignments

Terminal Description

1 (A-brn) Hot

2 (A-blu) Neutral 3 (A-grn/yel) Ground 4 (A-grn/yel) Ground

Table 2-6. Power Connections Terminal Assignments

Terminal Description

1 (B) Field Bus+ (Line) 2 (B) Field Bus- (Neutral) 3 (B) Ground

Foundation Fieldbus (option):

See also Wiring diagram 660198 – CAT 100 BASIC - at the end of this manual as attachment. This includes all wirings.

Maximum power requirements will be 180 watts, with most applications requiring less than this amount.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9

The optional case heater may increase power requirements to 380 watts.

NOTE

Instruction Manual

748441-D April 2002

Power

EMI Filter Bottom

1 21

1 4

Top

Figure 2-4. Increased Safety Junction Box Terminals

Model CAT100

NOTE:

If Foundation Fieldbus is selected then another terminal strip will be located between the power connection and the connector for the analog/digital/serial inputs and outputs (consult factory for further information).

2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

Instruction Manual

748441-D

April 2002

2-3 ANALYTICAL LEAK CHECK

If explosive or hazardous gas samples are being measured with the CAT 100, it is recommended that gas line fittings and components be thoroughly leak-checked prior to initial application of electrical power, bimonthly intervals thereafter, and after any maintenance which involves breaking the integrity of the sample containment system.

a. Flow Indicator Method

Supply air or inert gas such as nitrogen, at 10 psig (689 mbar), to the analyzer

10 psig

(690mbar)

through a flow indicator wi th a range of 0 to 250 cc/min. Install a shut-off valve at the sample gas outlet. Set the flow rate to 125 cc/min (ml/min).

Close the outlet shut-off valve and notic e that the flow reading drops to zero. If the flow reading does not drop to zero, the system is leaking and must be corrected before the introduction of any flammable sample gas or application of power.

CAT 100 Analyzer

Inlet Outlet

Flow Meter

Gas Outlet

Figure 2-5. Leak check - Flow Indicator Method

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-11

Instruction Manual

748441-D April 2002

Model CAT100

b. Manometer Method

Install a water-filled U-tube manometer at the sample gas outlet. Install a shut-off valve at the sample gas inlet. Admit air or inert gas to the inlet shut-off valve until the analyzer is pressurized to approximately 50 hPa. The water column will be about 500 mm.

Refer to Section 1-4 Specifications (page 1-11) for maximum pressure limitations.

For differential measurement, the leak check must be performed for the measurement and reference side separately.

For analyzers with parallel gas paths, the leak check must be performed for each gas path separately.

CAT 100 Analyzer

Inlet Outlet

Water

Figure 2-6. Leak Check - Manometer Method

NOTE:

Close the inlet shut-off valve and, following a brief period for pressure equilibrium, verify that the height of the water column does not drop over a period of about 5 minutes. If the water column height drops, the system is leaking and must be corrected before the introduction of any flammable sample gas or application of power.

Overpressure

pprox. 50 hPa

2-12 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

Instruction Manual

748441-D

April 2002

SECTION 3

OPERATION

3-1 STARTUP PROCEDURE

Once the CAT 100 has been correctly assembled and installed in accordance with the instructions in Section 2-2 (page 2-6), the analyzer is ready for operation.

Before operating the system, verify that the leak checks have been performed and that the sample handling unit is performing correctly.

Apply power to the system and verify that sample gas is flowing.

NOTE

A warm-up time of from 15 to 50 minutes is required depending on the installed detector(s).

Analyzer operation can be confirmed by the illumination of the LED displays through the glass window on the dome. Upon power up, the analyzer will perform a self-test routine. This display will initially show the program version number, after which the concentration values or error messages will display.

Program version display

(represents any character)

NOTE

In the case of a battery failure in the analyzer, the programmed values will revert to defaults and the display will flash “batt” on power up. This message will disappear after activating any pad. The battery maintains the memory for programmed parameters when the analyzer is shut off.

3-2 TOUCHPAD

a. Overview

CAT 100 analyzers intended either to be used in hazardous area or for outdoor use are provided with a Touch pad. This version ensures ingress protection (IP) and resistance against mechanical shocks.

The Touch pad design requires special measures to operate the analyzer in a safe manner. Due to safety reasons and to avoid unintended operation, the infrared sensitivity is adjusted in a way that the Touch pad may not activate without using the actuator tool.

b. Elements

Whereas standard front panels are using keys for operating the analyzer, the Touch pad uses contactless infrared technology. This results in a slightly different design.

Each panel key is replaced by two drilled holes: One for infrared light outlet and another for entry (Figure 3-1, page 3-1).

IR Outlet

Figure 3-1. CAT 100 Touch pad

IR Entry

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c. Actuator Tool

To operate the Touch pad, a Actuator Tool (PN 42715575) is required. Figure 3-2 (page 3-2) shows this tool as it is provided with each analyzer. If a replacement is required, contact Rosemount Customer Service Center.

Storing The Actuator Tool To store the actuator tool, attach the

actuator chain to one of the analyzer mounting bolts as shown in Figure 3-3 (page 3-2). The mounting provides a hook to store the actuator tool when not in use.

Figure 3-3. Storing The Actuator Tool

Figure 3-2. Touch pad Actuator Tool PN 42715575

d. Operation

The Touch pad is operated by reflecting the infrared light coming out of the drill hole into the corresponding entry hole.

This is done by holding the actuator tool’s bent end (Figure 3-2, page 3-2) in front of the key in a way that is aligned in parallel to the glass window surface.

A green light (“switch control”) is turned on when the actuator tool is in the correct position to activate the touch pad. On the CAT 100 it is placed right above the keys.

CAUTION.

Do not touch the glass window with the actuator tool to avoid scratching the window.

3-2 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

e. Functions

The operation and programming of the analyzer is performed using the infrared touch pad on the front panel. The parameters can be adjusted from the outside the enclosure without having to remove the dome. This can be accomplished by placing a finger over the appropriate location directly above the touch pad on the outside of the glass window. It is not necessary to make contact with the glass window.

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Position control

Figure 3-4. Touch pad Operation

The stored parameters are maintained during power off by the means of a battery powered memory. In the c ase of a battery failure in the analyzer, the programmed values will revert to defaults and the display will flash “batt” on power up. This message will disappear after activating any pad.

After a period of about 60 – 120 seconds in the absence of activating any pads, the analyzer will automatically revert to the “analysis display.”

Various prompts will appear on the two 4-digit LED displays.

300ppm CO

para.

FUNCTION ENTER INPUT CONTROL

SPAN 1 SAMPLE 3 SPAN 2 ZERO 4 PUMP SWITCH CTRL.

(channel labels will vary depending on configuration)

Figure 3-5. CAT 100 Analyzer Touch pad Function Identification

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f. FUNCTION Touch pad

Activating the FUNCTION pad addresses the individual analyzer Functions in sequence. Addressing an analyzer Function will not initiate any analyzer action or operation until the

ENTER pad is activated at the completion of an Input Control entry. The analyzer will continue to perform analysis throughout touch pad entry procedures.

The following are the analyzer Functions and their sequences:

Zeroing channel 1

Zeroing channel 2

Spanning channel 1

Spanning channel 2

Interval Time for automatic Zeroing

Interval Time for automatic Spanning

Entry of concentration limits

Entry of system parameters

Entry of serial interface parameters

Figure 3-6. CAT 100 Touch pad Functions

Only with combination of digital outputs and external solenoid valves, and if Auto = 1.

Only with optional RS 232 C/ RS 485 Serial Interface.

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Model CAT100

g. ENTER Touch pad

The Enter pad is used for the transfer of numerical data to the corresponding operating parameters and for the initiation of various operations, such as zeroing and spanning.

The first time the Enter pad is activated after selecting one of the Function sequences, the analyzer wi ll ask for a password code as shown below. This is to prevent tampering with the settings by unauthorized personnel. The password code is entered using the Input Control pads. If an incorrect password is entered, the CODE display will remain and the entry displayed will be reset to the value of “0.”

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Please use a password with two digits. See also item j for more information.

h. INPUT-CONTROL Touch pads

The Input-Control pads are used for the adjustment of the individual entry parameter values. Momentary activation of either pad will increase or decrease the values by 1.

∆ increases the current value by 1

DOWN by 1

If either pad is activated and held, the value will change continuously with the rate or change accelerating. When the minimal value is reached, the rate of change will slow in order to facilitate entry of the minimal value.

∇ decreases the current value

When the correct password has been entered, the Enter pad will sequence through the various entry modes as shown in Figure 4-2 and as described in the following sections.

The password has been set to the value “1” at the factory.

We would recommend to change the password immediately after start-up for safety reasons.

Each of the entry parameters is assigned an acceptable tolerance range which limits the range of values when entering parameters. In addition, all entries are subjected to a plausibility check as added protections against possible entry error.

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Optional

Figure 3-7. Analyzer Operating Function Matrix

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3-3 ENTRY OF SYSTEM PARAMETERS

To enter any or all of the System Parameters, activate the FUNCTION pad until

appears.

Then activate the ENTER pad. If the Password Code has not alre ady be en

entered, the following will appear:

Use the INPUT-CONTROL pads to select the proper Password Code and then activate the ENTER pad.

The following System Parameters will appear in sequence with successive activation of the ENTER pad. The individual parameters can be changed us ing the INPUTCONTROL pads prior to activating the ENTER pad.

NOTE

An optional pressure sensor with a range of 800 – 1100 hPa can be incorporated so that the concentration values will be automatically corrected for barometric pressure. In this case, it is not possible to enter the pressure value manually. Any attempt to enter the pressu r e value manually will be ignored and the analyzer will automatically revert to the measured pressure value.

b. Cross Compensation

This control permits switching the cross-compensation feature on and off. The cross-compensation feature is designed to minimize mutual interference between the two gases (i.e. CO CO) measured by the analyzer.

Entry of 0: Cross-compensation is disabled

and

a. Pressure Correction

To eliminate variations in measurement due to changes in barometric pressure or sample gas pressure, the current pressure can be entered expressed in hPa (mbar) in the range of 800 to 1300 hPa. The concentration values computed by the analyzer will then be corrected to reflect the barometric pressure or sample gas pressure respectively.

Use the INPUT-CONTROL pads to change the value and then activate ENTER.

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Entry of 1: Cross-compens ation is enabled

Use the INPUT-CONTROL pads to change the value and then activate ENTER.

c. Cross Compensation Calibration

Cross-Compensation correction factors are automatically determined during span adjustment if this feature is turned on. Pure test gases are required for this operation. Once cross-c omp en sation corrections have been determine d, span adjustments may be performed using test gas mixtures.

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Entry of 0: Spanning without crosscompensation correction (test gas mixture)

Entry of 1: Spanning with compensation correction (pure test gases)

Use the INPUT-CONTROL pads to change the value and then activate ENTER.

To perform a calibration with crosscompensation:

• First perform a zeroing for both channels.

•

Then perform a spanning for both channels

• Then repeat the spanning for the first analysis channel

NOTE

Both cross-compensation and cross-compensation calibration must be enabled in order to perform a correct calibration with crosscompensation correction! Use only pure test gases!

cross-

Entry of 1: The outputs will be locked during a calibration

Use the INPUT-CONTROL pads to change the value and then activate ENTER.

e. Automatic Calibration

This function enables or disables automatic-calibration when the analyzer is equipped with the optional internal or external solenoid valves. Digital outputs are also enabled.

Entry of 0: The outputs remain unlocked Entry of 1: The outputs will be locked

during a calibration Use the INPUT-CONTROL pads to

change the value and then activate ENTER.

f. Tolerance Check

NOTE

When using test gas mixtures, “C.Cal” must be set to zero!

d. Hold

The Hold function permits keeping the analog output signals and the concentration limits locked at the last measured values during a calibration procedure.

Entry of 0: The outputs remain unlocked

3-8 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

The Tolerance function is for the activation and deactivation of the tolerance check procedure for various calibration gases. If the tolerance check proced ure has been activated, during a calibration, the analyzer will indicate if the calibration shows a deviation of more than 10% from measuring range of zero or more than 10% of the nominal concentration value of span.

If this tolerance is exceeded, no calibration will be performed and an error message will appear.

Entry of 0: Tolerance check is deactivated

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Entry of 1: Tolerance check is activated Use the INPUT-CONTROL pads to

change the value and then activate ENTER.

g. Display Off

With this function on, the display will be disabled for about 1-2 minutes after the last pad activation. If any pad is activated while the Display is off, all display elements will be turned on without any further operation being initiated.

Entry of 0: Display is on Entry of 1: Display is off Use the INPUT-CONTROL pads to

change the value and then activate ENTER.

NOTE:

The zero and range values may be programmed. See Sections 3-3l (page 3-10) and 3-3m (page 3-10). For the type of voltage output, refer to the order confirmation or the identification plate.

See Section 2-2g (page 2-7) for terminal assignments of the analog outputs in the Increased Safety Junction Box.

i. Flushing Period

The Flushing Period establishes the dwell time for calibration gas flow during a calibration before the calibration reading is taken. The period may be selected in the range of 0-99 seconds depending on the calibration conditions. The calibration gas flow should be identical with the sample gas flow.

h. Analog Signal Outputs

This function switches the analog outputs from zero reference to life zero mode. The optically isolated analog outputs are available on the terminal block in the Increased Safety Junction Box.

Entry of 0: Output signal of 0-10 V (option 01- V) / 0-20 mA

Entry of 1: Output signal of 2-10 V (option 0.2-1 V) / 4-20 mA

Use the INPUT-CONTROL pads to change the value and then activate ENTER.

j. User Code

This is the password protection code used to prevent parameter ch anges by unauthorized persons. The value is fac tory set to “1” but may then be changed to another value. Be sure to record the user code in a safe place.

Use the INPUT-CONTROL pads to change the value and then activate ENTER.

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k. Response Time

For some types of analysis it may be desired to change the analyzer damping factor, i.e. its electrical response time or t90. This function allows the selection of an optimal t90 response time. The range of acceptable entries is 2-60 seconds.

Use the INPUT-CONTROL pads to change the value and then activate ENTER.

If the analyzer is equipped with a second channel, the t90 time for the second channel is also presented for adjustment.

l. Offset Value

NOTE

The analyzer is supplied from the factory with the offset set to 0. It is up to the user to change the valu e if desired.

m. Range Value

This function allows the user to establish a full scale range for the analog output signals.

Example: For an analyzer concentration range of

0-25% it is desired to measure concentrations only in the range of 0-15%. If the value of 15 is entered here , the analog signal outputs of 10 (1) V / 20 mA will then correspond to a gas concentration of 15%. The displayed values are not affected.

This function allows the user to establish a scale offset for the analog output signals.

Example: For an analyzer concentration range of

0-25% it is desired to measure concentrations only in the range of 10-2 5%. If the value of 10 is entered here, the analog signal outputs of 0 V / 0 mA or 2 (0.2) V / 4 mA will then correspond to a gas concentration of 10%. The dis played values are not affected.

Use the INPUT-CONTROL pads to change the value and then activate ENTER.

If the analyzer is equipped with a second channel, the offset for the second channel is also presented for adjustment.

Use the INPUT-CONTROL pads to change the value and then activate ENTER.

If the analyzer is equipped with a second channel, the range for the second channel is also presented for adju stment.

NOTE

The analyzer is supplied from the factory with the range set to full scale concentration range. It is up to the user to change the value if desired.

n. Reset

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The Reset function restores the analyzer settings to the parameters and calibration factors set in the factory.

This is the equivalent of switching off the power and disabling the battery retention of the memory by removing the battery jumper J7.

NOTE:

All parameters and calibration factors entered by the user will be lost whenever a reset operation is performed

The currently valid user password must be entered before a reset will be executed.

Use the INPUT-CONTROL pads to enter the password code and then activate ENTER.

Whenever a reset operation is performed, the analyzer operatin g program will be restarted, just as it is when the analyzer is first switched on.

Activate the ENTER pad to continue.

p. Serial Number

This function displays the analyzer serial number.

Activate the ENTER pad for the continuation of the serial number.

Activate the FUNCTION pad until the analyzer is back in the analysis mode.

q. Pump

This function turns the internal pump on or off. The state of the pump is retained when the power is shut off.

NOTE:

Jumper J6 on circuit board BKS, which activates the watchdog circuitry must be inserted if the reset operation is to be correctly executed. See Section 5-5a, page 5-29.

o. Program Version

This function displays the installed software version number. This number is also displayed when the analyzer is switched on.

Entry of 0: The pump is off. Entry of 1: The pump is on.

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3-4 CALIBRATION

To insure correct analyzer measurement, zeroing and spanning should be performed at least once per week . The span calibration must be performed after the zeroing.

For either manual or automatic calibration, the required test gases must be fed to the analyzer through the respective gas inlets with a no-back-pressure flow rate of about 1 l/min, the same as the sample gas.

NOTE:

After switching on the analyzer, wait at least approximately 15 to 50 minutes (depending on installed detectors) for instrument warm up before feeding gas to the analyzer.

NOTE:

If the optional internal or external solenoid valves are installed, the valves are automatically actuated by digital outputs for the respective function. If the analyzer is in “calibration mode,” an optional digital status signal “calibration” output is activated.

a. Zeroing

For zeroing, the analyzer has to be flushed with nitrogen (N quate zero gas such as synthetic or conditioned air. Air cannot be used for oxygen zeroing.

b. Spanning

The span gas concentration should be in the range or 80% to 110% of the full scale range of the analyzer. If lower span gas concentrations are used, the measuring accuracy for sample gas concentrations higher than the span gas concentration will be compromised. Spanning for oxygen measurement can be done using ambient air as span gas, if the oxygen concentration is known and constant.

NOTE

When using span gas mixtures, the entry for “C.Cal” must be set to “0” (see Section 3-3c, page 3-7)! If there is no built-in pressure sensor, the correct pressure must be entered before performing the calibration, if it is desired to have pressure correction (see Section 3-3a, page 3-7)!

) or an ade-

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3-5 MANUAL CALIBRATION

a. Zeroing

Zeroing will set the actual measured gas concentration to “zero.”

Activate the FUNCTION pad until the display shows:

Or (Zeroing channel 1 or channel 2) Activate the ENTER pad and the pass-

word code entry screen will appear. Using the INPUT-CONTROL pad, enter the correct password code and activate ENTER. The display will now show:

Or (The actual zero level) Wait at least the entered flushing time

and t90 time. Then activate the ENTER pad. The display will now show:

To start the zeroing process, activate ENTER again. As soon as the zeroing has finished, the display shows:

Or (The actual measuring value) The touch pad will only be released af-

ter another flushing period and t90 time. The analog output signals and the concentration limits are also released if Hold = 1.

To leave the calibration mode, activate FUNCTION.

b. Spanning

Spanning will set the actually measured gas concentration to the entered span gas set point. Verification of the span calibration is essential for accurate concentration measurement. Spanning can only be performed after performing or verifying the zero.

Activate the FUNCTION pad until the display shows:

Or (The nominal value) If the actual and nominal values agree,

zero calibration is not necessary and the next function can be selected using the FUNCTION pad.

If the actual and nominal values disagree, activate the ENTER pad and the display will show:

Or (The actual measuring value)

Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-13

(Spanning channel 1 or channel 2)

Activate the ENTER pad and enter the correct password code if not already entered. The display will now show:

(The actual concentration level)

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Wait at least the entered flushing time and t90 time. Then activate the ENTER pad. The display will now show:

(The test gas set point) If necessary, enter the true test gas set

point value taken from the manufacturer’s certification on the gas bottle using the INPUT-CONTROL pads and then activate ENTER. The display will now show:

(The actual measuring value) If the actual and nominal values agree,

span calibration is not necessary and the next function can be selected using the FUNCTION pad.

If the actual and nominal values disagree, activate the ENTER pad to start the spanning. As soon as spanning has finished, the display will show:

(The actual measuring value) The touch pad will only be released af-

ter another flushing period an d t90 time. The analog output signals and the concentration limits are also released if Hold = 1.

To leave the calibration mode, activate FUNCTION.

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3-6 AUTOMATIC CALIBRATION (OPTION)

A time-controlled automatic calibration can be established using internal or external solenoid valves activated by digital outputs. The automatic function of the analyzer must also be activated (see Section 3-3e).

With this optional function, the analyzer can perform an automatic calibration at preset time intervals. The t-AO and t-AS functions are available using the FUNCTION pad.

NOTE

For a time-controlled calibration procedure, the test gases must be fed through solenoid valves controlled by the analyzer in order to ensure the proper supply of test gases in the automatic calibration sequence.

If the test gas concentration has changed as a result of a new gas bottle being introduced, the set point must be manually entered per Section 3-5b.

Use the INPUT-CONTROL pads, enter a time interval in hours when automatic zeroing is to be performed. The range of accepted entries in 0 – 399 hours. Activate the ENTER pad to accept the entry.

Automatic zero calibration will first be initiated at the end of the interval entered referenced to the time of entry of the interval.

b. Combined Zeroing and Spanning

This function establishes an automatic spanning calibration after the automatic zero calibration.

Activate the FUNCTION pad until the following display shows:

Then activate the ENTER pad.

NOTE

If the entry is “0” (zero), the automatic calibration is switched off.

a. Zeroing

Activate the FUNCTION pad until the following display shows:

Then activate the ENTER pad. If the user password c ode has not yet

been entered, .the password entry display will show. Using the INPUTCONTROL pad, enter the correct password code and activate ENTER. The display will now show:

If the user password code has not yet been entered, .the password entry display will show. Using the INPUTCONTROL pad, enter the correct password code and activate ENTER. The display will now show:

Using the INPUT-CONTROL pads, enter a time interval in hours when automatic zeroing is to be performed. The range of accepted entries in 0 – 399 hours. Activate the ENTER pad to accept the entry.

Automatic zero and span calibration will first be initiated at the end of the interval entered referenced to the time of entry of the interval.

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3-7 CONCENTRATION LIMITS

Upper and lower alarm limits can be established for concentration measurement for each channel. The rightmost decimal of the respective display will blink whenever the concentration value falls outside a limit. Additional digital signal outputs for alarm limits are provided on the terminal block inside the Increased Safety Junction Box.

Activate the FUNCTION pad until the following displays:

Then activate the ENTER pad. If the user password code has not yet been

entered, .the password entry display will show. Using the INPUT-CONTROL pad, enter the correct password cod e and ac t i vate ENTER. The display will now show:

Use the INPUT-CONTROL pads to set the upper limit for channel 1. Then activate the ENTER pad and the following will appear:

Use the INPUT-CONTROL pads to se the lower limit for channel 2. Then activate the ENTER pad and the following will appear:

Use the INPUT-CONTROL pads to se the upper limit for channel 2. Then activate the ENTER pad to enter the value.

Activate the FUNCTION pad until the analyzer is back in the analysis display.

Use the INPUT-CONTROL pads to set the lower limit for channel 1. Then activate the ENTER pad and the following will appear:

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3-8 MEASUREMENT

The following summary steps must be observed for the proper measurement of sample gas concentration:

• After switching on the analyzer, allow it

to warm up for about 15 to 50 minutes, depending on the installed detectors.

• Admit sample gas to the gas inlet fit-

ting.

•

Switch on the optional sample gas pump.

•

Set the gas flow rate to the allowable range.

•

The analyzer must be in the analysis mode which is evidenced as follows:

Channel 1 concentration Channel 2 concentration

(if installed)

If some other display mode has been selected, the analyzer will automatically return to the analysis display after a period of 60 – 120 seconds has elapsed after the last pad activation or completion of an operation. Alternately, the user can activate the FUNCTION pad until the analysis mode displays.

Analyzers With Electrochem i ca l O tector:

The electrochemical O

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 sensitivity and the output will become unstable. The recommended practice is to purge the cell with conditioned ambient air between periods of measurement. If the oxygen concentratio n 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 one hour (ana-

lyzer zeroing) will have no effect on the sensitivity or stability.

De-

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3-9 SHUT DOWN

Before switching off the analyzer, it is recommend to purge the gas lines for abou t 5 minutes with zeroing gas (N

conditioned air. For analyzers with electrochemical O

detector, purge all analyzer

gas lines with conditioned ambient air before closing any gas line fittings for transport or storage of the analyzer. The full procedure for shutting down is as follows:

•

Admit zeroing gas to the respective gas inlet fitting.

•

Switch on the optional gas pump.

•

Set the flow rate to an allowable rate.

) or adequate

After 5 minutes:

• Switch off the analyzer.

•

Shut off the gas supply.

•

Close all gas line fittings immediately.

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3-10 TEMPERATURE STABILIZATION (OP-

TION)

Higher accuracy of concentration measurement as a function of temperature for the CAT 100 is achieved through the implementation of a controlled heater temperature within the enclosure. The temperature controller is mounted to the top of the analyzer and can be seen through the window.

The internal temperature of the analyzer is factory set to 50 °C. This internal temperature is suitable for ambient temperatures of up to 45 °C (50 °C max.).

For higher or lower expected ambient temperatures, the internal analyzer temperature can be set to the highest expected value but not above 50 °C. For instance, if the ambient temperature is not expected to exceed 30 °C, the temperature controller can be set to 30 °C, resulting in longer life for the heaters and temperature controller.

NOTE

If the temperature is changed from the factory setting of 50 °C, then the analyzer must be re-calibrated at the newly set temperature. See Sections 3-4 (page 3-12), 3-5 (page 3-13) or 3-6 (page 3-15) for calibration procedures.

a. Changing Temperature Settings

To change the internal temperature setting, remove the dome housing and adjust the set point to the desired value as described below.

SP2

MENU / MAX / MIN ENTER

Figure 3-8. Temperature Controller

1. Press MENU once. The display will flash the first digit of the set point.

2. Press MAX to set the digit from 0 to

3. Press MIN to activate the next digit.

NOTE

When equipped with this temperature stabilization option, allow the analyzer to reach operating temperature before making valid gas concentration meas-

4. Repeat these steps to set the other digits.

5. Press ENTER to store the setting and return to run mode.

urements. The ramp rate of the temperature controller is 20 °C/hr so adjust warm up time according to the am bient temperature and the controller set point.

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b. Controller Settings

If it is ever necessary to replace the temperature controller or if the settings get changed, the following describes the default settings that must be configured and the procedure to configure it properly.

Omega Engineering model CN77322 Controller settings for CAT 100:

DIP switch settings:

The DIP switch is accessible through an opening on the side of the case. After carefully removing the controller from the case, locate the DIP switch and set the switches according to the following:

ON OFF

Initial menu settings:

Upon applying power, the controller will first flash reset on the PV display and the software version number on the SV display, and then begin the Run Mode. Immediately press the MENU key to enter the Configuration Mode so that the controller does not begin to apply heat to the CAT 100. Alternately, press the ENTER key twice to enter the Standby Mode.

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Model CAT100

Mnemonic Description Menu Navigation (x = multiple presses)

SP1 = 50 Temperature set point 1 = 50 MENU-MAX-MIN-ENTER SP2 = 50 Temperature set point 2 = 50 MENU-MENU-MAX- MIN-ENTER

51.o.1 = 51.o.1 Output redirection = output 1 to 1 MENU-MENU-MENU-MAX- ENTER InPt tYPE = t.c Input Type = Thermocouple MENUX-ENTER-MAX-ENTER t.c = J Thermocouple type = J ENTER-MAX-ENTER dC.Pt = FFF.F Decimal Point = FFF.F MENUX(rdG CnFG)-ENTER(dEC.Pt)-ENTER-MAX-ENTER tEnP = C Temperature Units = C ENTER-MAX- ENTER FLtr = 0004 Filter Constant = 4 ENTER-MAX-ENTER Alr.1 = dSbL Alarm 1 = disable MENUX-ENTER-MAX-ENTER-ENTER L.b.AL = dSbL Loop Break Alarm = disable MENUX-ENTER-ENTER-MAX-ENTER-ENTER Id = dSbL ID Number = disable ENTER-ENTER-MAX-ENTER SELF = dSbL Manual, Self Control = disable MENUX(Out 1)-ENTER-MAX o0L0 = 0000 Percent Low = 0 MIN/MAX-ENTER o0HI = 0099 Percent High = 99 MIN/MAX-ENTER CtrL = On.OF Control Type = On, Off ENTER-MAX-ENTER Actn = rur5 Action Type = Reverse Acting ENTER-MAX-ENTER dEAd = 001.0 Dead Band = 1.0 ENTER-MAX/MIN-ENTER rANP = dSbL Ramp and Soak = disabled MENUX(rANP SoAC)-ENTER-ENTER-MAX-ENTER

Final menu settings:

Make sure the controller is in Run Mode. Allow the heater to reach the 50 C set point temperature. Enter the Configuration Mode again and change the following settings.

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Mnemonic Description Menu Navigation (

CtrL = PId Control Type = PID MENU-ENTERx(CtrL tYPE)-ENTER-MAX-ENTER Actn = rur5 Action Type = Reversing Action ENTER-MAX-ENTER AUto = EnbL Auto PID = Enabled ENTER-MAX-ENTER AdPt = EnbL Adaptive Control = Enabled ENTER-MAX-ENTER Antl = EnbL Anti-integral = Enabled ENTER-MAX-ENTER Strt = dSbL Start Auto PID = Disabled ENTER-MAX-ENTER CYCL = 0007 Cycle Time = 7 Seconds ENTERx(CYCL timE)-MAX/MIN-ENTER dPnG = 0004 Damping Factor = 4 ENTER-MAX-ENTER rANP = dSbL Ramp and Soak = Disable MENUx(rANP SoAC)-ENTER-MAX-ENTER

= multiple presses)

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SECTION 4

SERIAL INTERFACE OPTION

4-1 OVERVIEW

The CAT 100 analyzer can be equipped with a serial interface, enabling communication with a host computer. The host computer can read and alter parameters, as well as initiate analyzer operations, using standardized protocols. The option BSI circuit board constitutes the hardware interface. This can be configured as RS 232 C or as RS 485. The RS 485 interface permits the n etworking of several analyzers. Each analyzer may then be addressed using an assigned numerical ID code.

Communications are always initiated by the host computer. Thus, the analyzer is a passive device whereby the host requests information or takes an action such as changing parameters.

Communications between the host computer and the analyzer(s) is carried out with the transmission of a character string containing a specific syntax. The string always starts with the “$” (start character), immediately followed by a three-digit instruction code. Subsequent elements of the string are separa ted by the “:” hyphen character. The final element of all strings must be the “CR” carriage return character (terminate character).

Upon receipt of the terminate character, the analyzer attempts to evaluate the current contents of its input buffer as a valid string. If the syntax of the transmitted string is correct, the analyzer will transmit a response string to the

host computer. This consists of the s tart character, an instruction code, requ ested data, a block-parity byte, and the termination character.

If the syntax of the transmitted string was not correct, the analyzer will transmit to the host computer a status string containing an error message. Each terminate character receipt thus initiates an analyzer response.

To avoid detecting transmission errors, the host computer can inset a message-len gt h parity byte immediately prec eding the terminate character for verification b y the analyzer. The analyzer always transmits messagelength parity bytes immediately preceding termination characters.

The elapsed time between reception of start characters and termination characters is not limited by the analyzer; i.e., there is no timeout period.

If the host computer transmits any new characters before the analyzer has responde d to the preceding string, the analyzer’s input buffer will reject them; i.e., these characters will be ignored by the analyzer. The analyzer software is configured such that strings may be sent to the host computer at time intervals of 150 ms or greater.

The transmission rate may be set between 600 and 4800 baud.

An echo-mode may also be activated.

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Instruction Manual

748441-D April 2002

Model CAT100

4-2 PROTOCOLS

The analyzer is supplied from the factory with either PCB SIF232 or SIF485 connected to PCB BSI 10. This can be changed in the field.

The parameter 232c is also set to 0=NO or 1=YES.

a. RS 232

This interface required a shielded cable having at least three internal conductors.

b. RS 485

Configuration for either 2-wire or 4-wire operation is selected from LB1 on PCB SIP485. Connect pins 1-2 for 2-wire operation or pins 2-3 for 4-wire operation.

For network operation with several analyzers, jumper P2 must be installed at each end of the network. Analyzers inbetween must hav e P2 removed.

In contrast to RS232C operation, simultaneous transmission and reception is not implemented. Although there would be no damage to the electronics, simultaneous transmission and reception co uld lead to destruction of data. In this mode, the analyzer acts passively; i.e., it keeps its transceiver set for reception whenev er it is not transmitting. Since the time period for transmission and reception are estab lished by protocols, data collisions are prevented.

4-2 Serial Interface Option Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

Instruction Manual

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4-3 SETTING INTERFACE PARAMETERS

a. ON/OFF Status

The analyzer may be set to either “online” or “off-line” status. This setting may be performed either from the touch pad or by string instruction.

Status

On-Line Status Off-Line Status

If the analyzer is set to “off-line” status, it will accept only instruction code 6 from the host computer. All other instructions will be ignored and result in the transmission of the appropriate status strings.

b. Communication Parameters

The communication parameters between the analyzer and the host computer must agree for error-free communications. The following analyzer parameters can be set:

Baud rate: 600 / 1200 / 2400 / 4800 Data bits: 8 Stop bits: 2 Parity bit: none Echo mode: on / off (received charac-

LPB-test: on / off (message length

ID-number: 0 to 99 (device ID-number

Touch pad String

On.-L = 1 Code 6 On.-L = 0 Code 7

ters will be retransmitted immediately)

parity check)

in RS485 mode)

Settings

NOTE

All entries are made us the INPUTCONTROL pads and the ENTER pad.

Activate the FUNCTION pad until:

appears. Then activate ENTER. If the Password Code has not alre ady

been entered, the following will appear:

Use the INPUT-CONTROL pads to select the proper Password Code and then ac tivate the ENTER pad.

The analyzer is now ready for code entry by entering the following parameters and activating ENTER between each entry:

0 = off-line status 1 = on-line status

For RS485 operation only, each device is assigned a device number of 0-

99. Select interface

type: 0 = RS485 1 = RS232C

Set baud rate: 0 = 4800 1 = 2400 2 = 1200 3 = 600

Echo-mode operation: 0 = OFF 1 = ON

Message-block parity check: 0 = OFF 1 = ON

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Instruction Manual

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Model CAT100

4-4 STRING SYNTAX

Start Character (“$” = Hex 24)

If the start character is missing, this will result in transmission of the correspond status string by the analyzer.

Terminate Character (“CR” = Hex OD)

If the terminate character is missing, no decoding of the transmitted information will be performed and the analyzer will not respond. No response message will be transmitted.

Instruction Code

Each instruction is assigned a unique threedigit instruction code. If a received instruction code should be other than three digits in length or contain non-numerical ASCII charac-

ters, the analyzer will transmit an appropriate status string. Reception of unassigned instruction codes will also result in the transmittal of a status string.

In the RS232C mode of operation, the instruction code immediately follows the start character. In the RS485 mode of operation, the start character is followed by a two-digit device identification code, the separator character “;” and a three-digit instruction code, in that order.

Hyphen Character (“;” = Hex 3B)

Individual elements of a string line are separated by the hyphen character. Missing hyphen characters can lead to misinter pretat ions of the strings, and will result in transmission of a corresponding status string.

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Model CAT100

Instruction Manual

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a. Status Strings

If string syntax from the host computer is faulty, or the analyzer is unable to act on a received instruction, the analyzer will transmit a status string to the host computer as follows:

Status String

$ID;000;S100;LPB<CR> Unrecognized instruction code $ID;000;S101;LPB<CR> LP-byte in error $ID;000;S102;LPB<CR> Start character missing $ID;000;S103;LPB<CR> Input buffer overflow $ID;xxx;S104;LPB<CR> Analyzer off-line status $ID;xxx;S105;LPB<CR> Text line too long $ID;xxx;S106;LPB<CR> Undefined instruction $ID;xxx;S107;LPB<CR> Invalid integer value $ID;xxx;S108;LPB<CR> Numerical value outside defined range $ID;xxx;S109;LPB<CR> Invalid failure/status code $ID;xxx;S110;LPB<CR> Instruction cannot be done here $ID;xxx;S111;LPB<CR> Failure in transmitted character $ID;xxx;S112;LPB<CR> Zeroing running $ID;xxx;S113;LPB<CR> Spanning running $ID;xxx;S114;LPB<CR> Invalid real number $ID;xxx;S115;LPB<CR> Automatic calibration mode off $ID;xxx;S116;LPB<CR> Parameter outside defined range $ID;xxx;S117;LPB<CR> Pre-Flushing period is running

Where:

xxx: Instruction code ID: Device ID number in RS485 mode LPB: Message-length parity byte <CR>: Terminate character

Description

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Instruction Manual

748441-D April 2002

Model CAT100

b. Numerical Representations

Strings may contain integers or real numbers. The formats for these numbers are subject to the following restrictions:

Integers

Maximum value = 2 Only positive numbers are accepted

No decimal points allowed

Real

Maximum of 6 digits accepted No alphabetic characters allowed Analyzer output are 6-digit real

numbers

– 1

c. Block Parity Check

The host computer may insert a message-length parity byte into the strings. These must be two characters.

The message-length parity byte is the cumulative exclusive-or correlation of all previously transmitted characters of the string line. Representation is in hexadecimal format. For example, if the decimal value should be 13, the messagelength parity byte will be represented by the two characters “OD,” o30H and o44H.

The block parity check may be enabled or disabled at the analyzer (see Section 4).

4-6 Serial Interface Option Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

4-5 INSTRUCTION (RECEIVE) SYNTAX

Code definitions: RP: Rec eive parameters (analyzer is accepting values) SP: Send parameters (analyzer is sending values) RI: Receive instructions k: Channel numbers 0 to 1 m: Range number (always 1) w: Value <ID>: Device ID number in RS485 mode LPB: Message-length parity byte <CR>: Terminate character

a. Instruction Listing

Receipt of any instruction code not listed will be acknowledged by transmittal of status code 106. Future enhancements will make use of code numbers not currently in use.

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April 2002

Instruction String

$ID;001;k;LPB<CR> RI stand-by status $ID;002;k;LPB<CR> RI sample gas valve open $ID;003;k;LPB<CR> RI zeroing gas valve open $ID;005;m;k;LPB<CR> RI span gas valve open $ID;006;LPB<CR> RI on - line status $ID;007;LPB<CR> RI off - line status $ID;011;m;k;LPB<CR> SP at full scale range $ID;013;k;LPB<CR> SP t90 (response time) $ID;014;w;k;LPB<CR> RP t90 (response time) $ID;017;k;LPB<CR> SP pre-flushing period $ID;018;w;k;LPB<GR> RP pre-flushing period $ID;019;k;LPB<CR> SP Pre-Flushing period $ID;020;w;k;LPB<CR> RP Pre-Flushing period $ID;023;k;LPB<CR> SP concentration $ID;028;m;k;LPB<CR> SP span gas concentration $ID;029;w;m;k;LPB<CR> RP span gas concentration $ID;030;LPB<CR> SP status messages $ID;031;t;LPB<CR>

$ID;603;k;LPB<CR> SP gas component $ID;604;k;LPB<CR> RI automatic zeroing $ID;605;k;LPB<CR> RI automatic spanning $ID;606;0;LPB<CR> RI automatic zeroing and spanning $ID;627;LPB<CR> SP failure message (possible error batt. is clearing by read out) $ID;645;0;LPB<CR> SP pressure value $ID;646;w;LPB<CR>

Description

SP serial number (t=0, max. 10 characters) channel identification (t=1: ch.1, t=2: ch. 2)

SP solenoid valve status (w=1: Sample gas valve w=2: zero gas valve, w=4: span gas 1, w=8: span gas 2)

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Instruction Manual

748441-D April 2002

b. Response String Syntax

Response strings follow with the same syntax as the appropriate (SP-) commands. The response string for instruction:

$ID;030;LPB<CR> SP Status messages

Is as follows:

$ID;030;a;b;c;LPB<CR>

Where:

Model CAT100

Value

a: OK-Status 0 Relay without power 1 Relay active b: Calibration 0 No calibration 1 Zeroing channel 1 2 Zeroing channel 2 3 Zeroing channel 1 + 2 4 Spanning channel 1 5 Spanning channel 2 6 Spanning channel 1 + 2 7 Spanning channel 1 first, then channel 2 8 Reserved 9 Reserved 10 Waiting for flushing time and t90 response time c: Relay 3 0 Relay without power 1 Relay active

Meaning

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Model CAT100

Instruction Manual

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April 2002

SECTION 5

MAINTENANCE AND SERVICE

DANGER.

POSSIBLE EXPLOSION HAZARD

If explosive or hazardous gas samples are being measured, it is recommended that gas line fittings and components be thoroughly leak-checked prior to application of electrical power, bimonthly intervals, and after any maintenance which involves breaking the integrity of the sample containment system. Leakage of flammable samples could result in an explosion. See Sections 2-3 (page 2-11) and 6-2 (page 5-6) for Analytical Leak Check.

5-1 OVERVIEW

Maintenance of the CAT 100 can be summ a rized into three categories as follows:

a. Operating Factors

Many times a fault can be traced to operational omissions. Refer to the Troubleshooting Guide in Section 6 for tips on isolating typical faults. Also refer to Section 2 Installation and Section 3 Operation to verify that the analyzer is being operated properly.

Likewise, some faults can be traced to ancillary equipment. Check all equipment which is connected to the CAT 100, especially all gas paths, both sample and calibration.

b. Analyzer Replacement

The CAT 100 is uniquely designed so that the analyzer component can be eas ily removed from the explosion proof housing and replaced. For critical service applications, a spare analyzer can be maintained and replacement can be effected in a matter of minutes to have the process back into operation with minimal interruption.

c. Analyzer Repair

Ultimately, the analyzer component may need maintenance and/or service. See the Troubleshooting Guide in Section 6 for typical failure remedies, Section 5 for maintenance operations, and service of analyzer internal components. Refer to the CAT 100 Assembly Drawing 659921 located in the rear of this manual.

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Model CAT100

5-2 COMPONENT REMOVAL

DANGER.

POSSIBLE EXPLOSION HAZARD

If explosive or hazardous gas samples are being measured with the CAT 100, it is recommended that the system be purged with air or inert gas such as nitrogen before opening the explosion proof housing. Failure to purge the housing before opening could result in an explosion.

WARNING.

ELECTRICAL SHOCK HAZARD

Disconnect power from the CAT 100 before opening and removing any components. Failure to remove power can result in electrical shock.

The CAT 100 explosion proof enclosure is comprised of three major sections; the base, the extender housing and the dome housing. These are shown in Figure 5-1 (page 5-2).

The three sections are threaded together. To remove, turn counterclockwise and to replace turn clockwise. Use an anti-seizing compound on the threads when required.

O-Ring

Base

Retaining Ring

Extender Housing

O-Ring

Dome Housing

Glass Window

Figure 5-1. CAT 100 Enclosure Assembly

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Model CAT100

Instruction Manual

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April 2002

a. Analyzer Removal

1. Refer to drawing 659921 for location of components.

2. Remove only the dome housing from the extender ring.

3. Mark the location of the screws on each analyzer mount using a fine tip marker. It is important that the analyzer be replaced in the exact same location so that the light guides touch the inside of the glass window.

4. Loosen, do not remove, the screws (17) holding the swing tab (14) on each analyzer mount (2) and swing the tab clear of the slot.

5. Loosen, do not remove, the six screws (23) holding the analyzer.

6. Slide the analyzer forward being careful of the umbilical cables and gas lines attached.

7. Disconnect all electrical connections and gas lines and remove the analyzer component for repair or replacement.

8. Close all gas line fittings with PVC caps after removal of the analyzer.

2. Locate the analyzer in the exact same location as when removed by aligning the screws with the alignment marks previously made.

3. Tighten the screws.

4. Make sure the dome threads are clean and free of any contaminants.

5. Replace the dome housing, by lining up the reference marks so that the threads engage properly. If any resistance is felt, remove the dome and clean the threads.

6. Make sure that the spring loaded light guides just touch the inside of the glass window. Failure to have the light guides touching the glass window can result in spontaneous menu navigation.

c. Power Supply Assembly Removal

1. Follow the process for analyzer removal in Section 5-2a (page 5-3).

2. Disconnect all wires from the power supply terminal block.

3. Loosen, do not remove, the three screws (17) holding the power supply assembly.

b. Analyzer Replacement

1. Slide the analyzer onto the mounts, being careful that the screws and washers are on the outside.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 5-3

4. Slide the power supply assembly in its slotted holes and remove.

5. Reverse the process for installation.

Instruction Manual

748441-D April 2002

Model CAT100

5-3 ANALYZER CONFIGURATION AND AD-

JUSTMENT

The following is a brief description of the internal hardware of the analyzer to familiarize the maintenance technician with the location of parts for service. It should be understood that this is an example only, as the configuration of the analyzer can depend on the install detectors and number of channels, one or two.

a. Component Layout

Depending on the installed options, the analyzer can include the following detectors:

• One Infrared Photometer

• One 02 Sensor (paramagnetic or elec-

trochemical)

•

Two Infrared Photometer

•

One 02 Sensor (paramagnetic or electrochemical) and one Infrared Photometer

In addition, the following major components may be present:

• Gas sampling pump with a maximu m

pumping rate of 2.5 l/min (not included on two channel analyzer with parallel gas paths). An indicator light is provided on the front panel to show when the pump is on.

•

Option pressure sensor (range of 800 to 1100 hPa). With the pressure sensor installed, the concentrations values computed by the analyzer will be corrected to reflect the barometric pressure to eliminate faulty measurements due to changes in barometric pressure.

•

An optional solenoid valve unit (not included on two channel analyzer with parallel gas paths).

• For this example, there are 4 built-in so-

lenoid valves: Sample Gas, Zero Gas, Span Gas 1, and Span Gas 2.

•

An indicator light on the front panel shows if a solenoid valve is open.

The location of these major components are show in Figure 5-2 through Figure 5-5.

5-4 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

(

Solenoid Valves

FOUNDATION Fieldbus (option)

Digital Inputs (option)

Paramagnetic Oxygen Sensor (depending on ana-

Figure 5-2. Analyzer Component Layout (Infrared Channel / Oxygen Measurement, Combined)

(Channel 1, alt)

(Channel 2)

Front Panel

Instruction Manual

748441-D

April 2002

Circuit board BKS

under photome-

IR Photometer (depending on ana-

Electrochemical Oxygen Sensor with circuit board OXS

Pressure Sen-

Gas Sampling Pum

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Instruction Manual

748441-D April 2002

Solenoid Valves

FOUNDATION Fieldbus

Digital Inputs (option)

Figure 5-3. Analyzer Component Layout (1 Channel Oxygen Measurement, Electrochemical)

Model CAT100

Circuit board BKS

(Channel 1)

Electrochemical Oxygen Sensor with circuit board

Pressure Sen-

Gas Sampling Pump

Front Panel

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Instruction Manual

(dep

Model CAT100

Solenoid Valves

FOUNDATION Fieldbus

Digital Inputs (option)

Thermal Conductivit

Paramagnetic Oxygen Detector

ending on ana-

Figure 5-4. Analyzer Component Layout (Paramagnetic Oxygen Measurement / Thermal Conductivity,

Combined)

Front Panel

Circuit board BKS

Thermal Conductivity Detector

ending on ana-

Pressure Sen-

Gas Sampling Pump

748441-D

April 2002

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Instruction Manual

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(

748441-D April 2002

Solenoid Valves

FOUNDATION Fieldbus

Digital Inputs (option)

Thermal Conductivit

(Channel 1)

Channel 2,

Thermal Conductivity Detector

ending on ana-

Figure 5-5. Analyzer Component Layout (Infrared Channel / Thermal Conductivity, Combined)

(Channel 2)

Front Panel

Model CAT100

Circuit board BKS

IR Photometer (depending on ana-

Electrochemical Oxygen Sensor with circuit board

Pressure Sen-

Gas Sampling Pump

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b. Photometer Assembly

Depending on the gas component being measured and the concentration range, different photometer assemblies will be installed in the analyzer. In addition, a sealed photometer can be supplied in which case all parts are sealed with Orings.

The entire photometer assembly is mounted as a unit on the main circuit board (BKS) by means of a bracket. The main circuit board is inserted into guide rails in the analyzer housing, to which the front panel and rear panel are attached.

Photometer with Pyroelectrical Detector (Solid-State Detector)

Figure 5-6 (page 5-10) shows the layout of the photometer assembly for a dual channel configuration.

The base element for the photometer assembly is the chopper housing (03), on which the light source (thermal radiator,

07), the analysis cell (cuvette, 09), and the signal detection unit [filter cell (14/15), pyroelectrical (solid-state) detector with integrated preamplifier (16)] are all mounted. The chopper hous ing al s o incorporates the duplex filters (04/05) for the selection of spectral band-pass ranges from the broadband emission of the light sources.

Between the two halves of the chopper housing (03), which are sealed together with an 0-ring, is the chopper blade, driven by a stepping motor. Both the chopper housing and the motor encapsu-

lation are hermetically sealed with respect to ambient in order to prevent entry of gases such as atmospheric CO

which

could produce background absorptivity (pre-absorption), leading to drift effects. An absorber material provides for constant removal of any traces of C0

which may

enter the interior of the chopper housing by diffusion.

The chopper housing additionally incorporates a photoelectric gate for providing a reference signal for the phase angle of the chopper blade, plus a temperature sensor (28) for continuously monitoring the photometer assembly temperature. This temperature information is used by the signal processing electronics for the compensation of thermal effects.

The analysis cells are merely aluminum tubes equipped with sample gas inlet and outlet fittings. This extremely simple and windowless design enables easy cleaning of the cells in the event of contamination. The only optical surfaces which also might become contaminated are the chopper windows and the windows of the filter cells; these are accessible upon removal of the cell body.

The filter cell (14/15) has a necked conical shape for optimal adaptation of the analysis cell beam cross-sectional profile to the active area of the detectors.

For high measurement ranges (up to 100%)

an adapter cell (10) is required.

The use of a spacer ring (08) creates an analysis cell in the space between the exit window of the adapter cell and the entrance window of the filter cell.

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Instruction Manual

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06 28

17 26

Model CAT100

Legend:

03 Chopper Housing 04/05 Duplex Filter Disc 06 Zero Adjustment Baffle (not in sealed photometer) 07 Light Source (thermal radiator) 08 Analysis Cell 1-7 mm (spacer ring) 09 Analysis Cell 50-200 mm 10 Adapter Cell 14/15 Filter Cell 16 Detector 17 Flange (light source) 18-21 O-Rings 22 Clamp (analysis cells 1-7 mm) 23 Clamping Collar (analysis cells 1-7 mm) 25 Clamp (analysis cells 50-200 mm) 26 Light Source Mounting Screws 27 Mounting Screws for Analysis Cells / Adapter Cells 28 Temperature Sensor

19 14

21 25

09 03

Figure 5-6. Photometer Assembly with Pyroelectrical Detector

16 19

23 08

21 10 20

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Instruction Manual

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Photometer with Gas Detector

Figure 5-7 (page 5-11) shows the layout of the photometer assembly. This assembly is similar to the assembly with pyroelectrical detector.

The analysis cells are separated into two halves by means of an internal wall along its axis and both ends are sealed with windows. This divides the analysis cell into measuring side and reference side. Sample gas flows through the measuring side while the closed reference side contains inert gas (N

High Measuring Range Combined With Electrochemical O

nalysis

Filter Cell

Gas Detector

Low Measuring Range Combined With Electrochemical O

Analysis Cell

Absorber

Preamplifier

Figure 5-7. Photometer Assembly with Gas Detector

To prevent measuring errors by preabsorption. Two absorbers, fitted to the gas connectors of the reference side, absorb CO

The filter cell has a single-stage conical shape. The gas detector is connected by a shielded cable to a preamplifier. For small measuring ranges, the preamplifier is mounted at the analysis cell. For high measuring ranges, the preamplifier is mounted by two holding clamps.

Measurement

Holding Device

Measurement

Preamplifie

components.

Holding Device

Absorber

Gas Detector Filter Cell

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c. Analyzer Rear Panel

1 2 3 4 5 6 7 8 9

K1 K2 K1 K2

IN OUT

ANALOG IN

X1 OUTPUT

X4 IN/OUT

X2 OUTPUT

FLOW RATE MAX. 1L/MIN

X3 OUTPUT

SPAN 2

SAMPLE

OUT

24 V max 120W

ZERO

10 11 12 13 14 15 16 17

1. Gas inlet fitting.

2. Gas inlet fitting. Channel 2 parallel path. (option)

3. Gas outlet fitting.

4. Gas outlet fitting. Channel 2 parallel path. (option)

5. Cross compensation inputs. (option)

6. Solenoid valve calibration gas inlet 1. (option)

7. Solenoid valve calibration gas inlet 2. (option)

8. Solenoid valve common gas outlet fitting. (option)

9. Digital inputs. (option)

10. Socket, analog signal outputs X2.

11. Socket, serial interface. (RS232C/485) (option)

12. Plug, output relays. (option)

13. Plug, digital limit outputs.

14. Solenoid valve sample gas inlet. (option)

15. Solenoid valve zero gas inlet. (option)

16. 24 VDC input.

17. Foundation Fieldbus. (option)

Figure 5-8. Analyzer Rear Panel Layout

Model CAT100

DIGITAL IN

5-12 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

(

)

X1 OUTPUT

Optional Output Relays

9-Pos D-Subminiature Plug

1 2 3 4 5 6 7 8 9

X3 OUTPUT Digital Outputs (Optically isolated)

9-Pos D-Subminiature Plug

1 2 3 4 5 6 7 8 9

X4 OUTPUT

9-Pos D-Subminiature Socket

Optional RS232C Interface (optically isolated)

1 2 3 4 5 6 7 8 9

ANALOG IN

Optional Cross Compensation inputs

9-Pos D-Subminiature Plug

1 2 3 4 5 6 7 8 9

Figure 5-9. Pin Assignments (View Looking At Rear Panel)

OK / Failure (NC) OK / Failure (NO) Measure / Calibration (NC) Measure / Calibration (NO) Pump OFF (NO) / ON (NC) OK / Failure (Common) Measure / Calibration (Common) Pump OFF / ON (common) Pump OFF (NC) / ON (NO)

NO = Normally open NC = Normally closed

Limit channel 2 max Limit channel 2 min Limit channel 1 max Limit channel 1 min Gnd (Valve control span gas 2) (Valve control span gas 1) (Valve control zero gas)

Valve control sample gas

Gnd RxD TxD Not used Gnd Not used Not used Not used Not used

Interfering gas 1

Gnd

Interfering gas 1 Interfering gas 2

Gnd

Interfering gas 2 Not used Interfering gas 3 (Gnd) Interfering gas 3 Not used Not used

X2 OUTPUT

Analog Outputs (optically isolated)

9-Pos D-Subminiature Socket

Optional RS485 Interface (optically isolated)

1 2 3 4 5 6 7 8 9

Gnd RxDRxD+ TxD+ TxDNot used Not used Not used Not used

24 V DC IN

Pin 1 = Chassis

Pin 2 = +24V DC

Pin 3 = 0V DC

Flange = Shield

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April 2002

1 2 3 4 5 6 7 8 9

Gnd (V DC) 0(2)-10 VDC* Channel 1 0(4)-20 mA Channel 1 0(2)-10 VDC* Channel 2 0(4)-20 mA Channel 2 Return (mA) Return (mA) Return (mA) Return (mA)

*Option: 0(0.2)-1 VDC

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Model CAT100

d. Thermal Conductivity Response Time

The thermal conductivity response time (to 90 % of full scale indication) may be adjusted by resetting the positioning of the transverse passages of the gas cell relative to the gas fittings. The adjustment procedure is as follows:

Remove the analyzer from the dome housing in accordance with Section 5-2a (page 5-3).

Remove the top cover from the analyzer. The thermal conductivity se nsor can now

be seen. The two Allen-head screws in the milled out sections mark the positions of the transverse passages for the sample gas. As supplied, these passages are set aligned with the gas fittings (see Figure 5-10, page 5-15). This means that the instrument is supplied as standard set for a

short response time and a relatively large dependence on sample-gas flow rate.

To alter the response time, loosen the Allen-head screws on the sensor, and rotate the outer annular chamber section.

The greatest response time and least dependence on sample-gas flow rate will be obtained when the two screws are near the ends of the milled-out sections (see Figure 5-11, page 5-15).

The sensor positioning may be varied to obtain response times between the two extremes. The response time may be measured using a test gas mixture.

When the sensor positioning (response time setting) appropriate for the application has been obtained tighten the two Allen-head screws, and replace the instrument top cover.

5-14 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

Figure 5-10. TC Sensor Short Response Time Setting (Standard)

Instruction Manual

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April 2002

Figure 5-11. TC Sensor Long Response Time Setting

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748441-D April 2002

Model CAT100

5-4 MAINTENANCE

a. Routine and Preventive

In general only the gas conditioning hardware will require maintenance. The analyzer itself requires very little maintenance.

The following checks are recommended for proper continued operation of the analyzer:

•

Check and adjust zero level (Section 34a, page 3-12): Weekly

• Check and adjust span (Section 3-4b, page 3-12): Weekly

•

Perform leak check (Sect ions 2-3, page 2-11 and 6-2, page 5-6): Bi-monthly

The maintenance frequencies stated above are presented as guidelines only. These and other maintenance operations may be required more or less frequently, depending upon experience, usage and site conditions.

b. Checking and Cleaning of the Analyzer

If the analyzer is removed from the explosion proof enclosure for any reason, it should be cleaned and the electronics checked for any obvious faults.

1. Remove the analyzer from the enclosure (see Section 5-2a, page 5-3)

2. Clean the outside of the analyzer with a moistened lint-free cloth using a cleaning solution of 3 parts water and 1 part all-purpose detergent. Do not use a wet cloth and be sure no liquid can drop into the analyzer components.

3. Remove the analyzer cover by removing the 4 screws on each side.

4. If necessary, remove the front panel by removing the 3 screws on each side.

5. Clean and inspect all components as necessary.

5-16 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

6. Re-assemble the analyzer front panel and cover in the reverse order.

Model CAT100

Instruction Manual

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April 2002

c. Cleaning and Replacement of Photo-

metric Components

and the electronic unit and remove all gas lines from the photometer assembly.

Removal of Photometer Assembly

1. Remove the analyzer from the enclosure (see Section 5-2a, page 5-3)

2. Remove the analyzer cover (see Section 5-4b, page 5-16)

3. Disconnect all electrical connections between the photom eter assembly

4. On analyzers with gas detector, remove preamplifier (Figure 5-7, page 5-11) from holding device .

5. Remove the two screws shown in Figure 5-12 (page 5-17) as item 1.

6. Remove the photometer assembly from the analyzer housing as a unit.

1) Fastening screw, photometer assembly mounting bracket

2) Light source with mounting flange

3) Temperature sensor

4) Zero-level adjustment baffle (not on sealed version)

5) Light source mounting screw

Figure 5-12. Analyzer Photometer Assembly ( 2 Channel Infrared Analyzer, Viewed From Front Panel Side)

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 5-17

Instruction Manual

748441-D April 2002

Model CAT100

d. Light Source Replacement

1. Remove the analyzer from the enclosure (see Section 5-2a, page 5-3)

2. Remove the analyzer cover (see Section 5-4b, page 5-16)

3. Remove the photometer assembly from the analyzer housing (see Sec tion 5-4c, page 5-17)

4. Remove the two light source mounting screws and the temperature sensor show in Figure 5 -12 (page 5-17) as item 5 and item 3 respectively.

5. Remove the light source together with its mounting flange.

6. Remove the mounting flange from the light source and position it on the new light source.

7. For sealed version with pyroelectrical detector only, remove the zero-level adjustment baffle from the light source and position it in the new light source.

8. For sealed version only, place the Orings on the adapter cell and filter cell.

9. Insert the new light source and flange in the same position as the old one.

10. Insert and tighten the two light source mounting screws and the temperature sensor shown show in Fig ure 5-12 (page 5-17) as item 5 and item 3 respectively.

11. Replace the photometer assembly in accordance with Section 5-4c, page 5-17.

12. Perform the physical zeroing procedure in Section 5-4i, page 5-20.

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Instruction Manual

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April 2002

e. Removal of Analysis Cells

1. Remove the analyzer from the enclosure (see Section 5-2a, page 5-3)

2. Remove the analyzer cover (see Section 5-4b, page 5-16)

3. Remove the photometer assembly from the analyzer housing (see Sec tion 5-4c, page 5-17)

For analysis cells of 1 mm and 7 mm length:

1. Remove the clamp shown in Figure 5-13 (page 5-19) as item 2.

2. Remove the clamping collar and the filter cell with signal detector assembly.

1) Filter cell with signal detector assembly

2) Clamp with clamping collar

3) Clamp

4) Mounting screws for analysis cells of 50 – 200 mm length

4 2

Figure 5-13. Photometer Assembly

For analysis cells of 50 mm to 1 00 mm length:

1. Remove the clamp shown in Figure 5-13 (page 5-19) as item 3.

2. Remove the filter cell with signal detector assembly.

3. Remove the mounting screws shown in Figure 5-13 (page 5-19), item 4.

4. Remove the analysis cell body from the chopper housing.

5. On analyzers with a gas detector, remove the preamplifier from the analysis cell.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 5-19

Instruction Manual

748441-D April 2002

Model CAT100

f. Cleaning of Analysis Cells and Win-

dows

Windows:

The shielding windows on the filter cell, chopper housing, and the adapter cell, may be cleaned with a soft, lint-free cloth. Use a highly volatile alcohol for the cleaning procedure. Remove any lint and dust particles remaining by blowing off the cleaned components with nitrogen.

Non-Divided Analysis Cells:

The analysis cell may be cleaned with a soft, lint-free cloth. Use a highly volatile alcohol for the cleaning procedure. Remove any lint and dust particles remaining by blowing off the cleaned components with nitrogen.

Divided Analysis Cells:

If deposits are visible in the analysis cell, these can be removed with a suitable solvents such as acetone. Then the analysis cell is to be flushed with an alcohol which evaporates easily and dried by blowing nitrogen.

as shown in Figure 5-13 (page 5-19), item 4.

3. Place the O-rings on the filter cell.

4. Fit the filter cell on the cell body.

5. Install the clamp and tighten.

6. For an analyzer with a gas detec tor, assemble the preamplifier to the analysis cell.

7. Replace the photometer assembly as described in Section 5-4h (5-20).

h. Reinstalling Photometer Assembly

1. Insert the photomet er as se mbly into the analyzer housing and fasten in position using the mounting bracket screws as shown in Figure 6-13, item

2. For an analyzer with a gas detec tor, insert the preamplifier (Figure 5-13, page 5-19, item 5) into the holding device (Figure 5-13, item 4)

NOTE

The maximum pressure in the analysis cell is 1,500 hPa!

g. Reinstalling Analysis Cells

For analysis cells of 1 mm and 7 mm length:

1. Place the O-rings on the adapter cell and filter cell.

2. Fit the components together.

3. Install the clamping collars with the clamp and tighten.

For analysis cells of 50 mm – 200 mm length:

1. Place the O-ring on the chopper housing side of the cell body.

2. Position the cell body in place and fasten using the two mounting screws

3. Reconnect all gas lines to the assembly.

4. Reconnect all electrical connectors between the photometer assembly and the electronic unit (see Section 55a).

5. Perform a leak check (see Sections 23, page 2-11 and 6-2, page 5-6).

6. Perform the physical zeroing procedure (see Section 5-4i, page 5-20).

i. Physical Zeroing

Adjustment of the physical zero level will only be required if a light source, a filter cell, or an analysis cell have been replaced or repositioned.

The adjustment will required the use of a digital voltmeter (DVM) with a range of 2 VDC and a 3 mm hexagon wrench.

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Instruction Manual

748441-D

April 2002

1. Switch on the analyzer.

2. Admit zero gas to the analyzer.

3. Connect the DVM to the following measuring points:

X 25 and X 28 for channel 1 (infrared measurement only).

X 27 and X 28 for channel 1 (combined oxygen / infrared measurement)

X 27 and X 28 for channel 2 (IR measurement only).

Standard Photometer (not sealed version):

1. Slightly loosen the light source mounting screws (Figure 5-13, page 5-19, item 5) or the temperature sensor (Figure 5-13, item 3) respectively for channel 1 or channel 2.

2. Set the zero level precisely to 0 V (± 100 mV) by turning the corresponding light source. If the turning of the light source is not sufficient, the zero point can be adjusted by sliding the zerolevel adjustment baffle (Figure 5-13, page 5-19, item 4).

3. Tighten the light source mounting screws (Figure 5-13, item 5) or the temperature sensor (Figure 5-13, item

3) respectively for channel 1 or channel 2.

2. Set the zero-level to precisely 0 V (± 100 mV) by turning the corresponding light source.

3. For photometer with pyroelectrical detector only:

a. To facilitate the physical zero-

level adjustment, there is built into the light source, one of three different tight baffles (zero-level adjustment baffles). For simplicity of exchange, the baffle is held into the light source by a magnet. If the turning of the light source is not sufficient, another tight baffle can be used to position the light source.

4. Tighten the light source mounting screws (Figure 5-13, page 5-19, item 5) or the temperature sensor (Figure 5-13, item 3) respectively for channel 1 or channel 2.

5. When the physical zeroing has been correctly set, perform an electrical zeroing as described in Section 3-4a page 3-12.

j. Replacement of Electrochemical Oxy-

gen Sensor

Because of the measuring principle utilized in the electrochemical oxygen sensor, the sensor will have a limited life time.

4. When the physical zeroing has been correctly set, perform an electrical zeroing as described in Section 3-4a, page 3-12.

Sealed Photometer Option:

1. Slightly loosen the light source mounting screws (Figure 5-13, page 5-19, item 5) or the temperature sensor (Figure 5-13, item 3) respectively for channel 1 or channel 2.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 5-21

The life time of the oxygen sensor is dependent on the sensor itself and on the measured oxygen concentration and is calculated as follows:

Life time =

The sensor time (operation without oxygen at 20 °C) is:

•

Sensor time (hours) O

concentration (%)

About 900,000 hours for a sensor with a response time of about 12 s

Instruction Manual

748441-D April 2002

Model CAT100

• About 450,000 hours for a sensor with

k. Check of the Sensor

a response time of about 6 s The sensors have the following life time at about 21% oxygen and 20 °C:

•

About 42,857 hours (5 years) for a

sensor with a respons e time of about

Exchange the sensor if the voltage is less than 70% of the initial output voltage.

The check requires a digital voltmeter (DVM) with a range of 2 V DC.

12 s

•

About 21,428 hours (2.5 years) for a

sensor with a respons e time of about

1. Remove the analyzer from the encl osure (see Section 5-2a, page 5-3)

6 s The values stated above are presented as guidelines only. Actual values will depend

2. Remove the analyzer cover (see Section 5-4b, page 5-16)

on measured concentrations and operation temperature. The result of higher

3. Switch on the analyzer.

temperatures, for example 40 °C, could be half the life time.

4. Admit ambient air to the analyzer of about 21% O

NOTE

The electrochemical O

cell requires a

minimum internal consumption of oxygen. Sample gase s with an oxygen concentration of less than 0.1 % could result in a reversible detuning of sensitivity and the output will become unstable. The recommended practice is to purge the cell with conditioned ambient air between periods of measurement. If the oxygen concentration is below 0.1 % for several hours or days, the cell must be regenerated for about one day with ambient air. Temporary flushing with nitrogen (N one hour (analyzer zeroing) will have no effect on the sensitivity or stability.

) for less than

TP1

TP2

5. Connect the DVM to the following measuring points:

a. TP1 (signal) and TP2 (gnd) of

the OXS PCB, mounted directly at the connection block (see Figure 5-14, page 5-22).

b. The voltage should be in the

range of 700 mV to 1000 mV DC. If the voltage value is lower that 700 mV at gas flow with ambient air, the sensor is consumed and must be replaced.

Figure 5-14. OXS PCB Measuring Points

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Instruction Manual

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April 2002

l. Removal of the Sensor

Oxygen Measurement without Infrared Channel:

1. Remove the analyzer from the enclosure (see Section 5-2a, page 5-3)

2. Remove the analyzer cover (see Section 5-4b, page 5-16)

3. Disconnect all electrical connections between the PCBs OXS and BKS, connectors X5, X6, and X7 (refer to Section 5-5a, page 5-29).

4. Remove all gas lines from the sensors.

5. Unscrew both allen screws shown in Figure 5-15, page 5-23.

6. Remove the support bracket from the top of the analyzer.

7. Disconnect the connector P2 from the OXS PCB (see Figure 5-16, page 5-

24).

8. Cut and remove the tie wrap as shown in Figure 5-17, page 5-24.

9. Unscrew both fastening screws for the fitting (see Figure 5-17, page 5-

24).

10. Remove the fitting including the sensor as shown in Figure 5-17, page 5-

24.

Gas connections

llen screw

Front Panel

Figure 5-15. Oxygen Sensor without Infrared Channel

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Instruction Manual

748441-D April 2002

Figure 5-17. Oxygen Sensor Support (Oxygen Measurement Without Infrared Channel)

OXS PCB

Sensor

Sensor nameplate

Oxygen Sensor Connector P2

Figure 5-16. OXS PCB Connector P2

Connector for

Potentiometer R4

Fastening screw

Tie Wrap

Fastening screw

Fitting

Model CAT100

Gas connections

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Model CAT100

Instruction Manual

748441-D

April 2002

Oxygen Measurement combined with infrared Channel:

1. Remove the analyzer from the enclosure (see Section 5-2a, page 5-3)

2. Remove the analyzer cover (see Section 5-4b, page 5-16)

3. Disconnect the connector P2 from the OXS PCB (see Figure 5-16, page 5-

24).

4. Unscrew both fastening screws for the fitting (see Figure 5-18, page 5-

25) and remove the fitting complete with the sensor.

Fastening screws

Figure 5-18. Oxygen Sensor with Infrared Channel

Gas connections

Fitting

Front Panel

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Instruction Manual

748441-D April 2002

Model CAT100

Exchange of the Sensor

1. Remove the spent sensor from the fitting.

2. Remove the stopper from the new sensor and place the new sensor into the fitting, so that the name plate is at the top of the sensor.

3. Close the used sensor with the stopper and return it to the factory immediately.

Reinstalling the Sensor Oxygen Measurement without Infrared

Channel:

1. Put the fitting with the new sensor onto the support. Position to the stop and fasten with the two screws (see Figure 5-17, page 5-24).

2. Fix the sensor with a tie wrap at the support as shown in Figure 5-17, page 5-24.

3. Connect the cable from the sensor to P2 of OXS PCB (see Figure 5-16, page 5-24).

4. Insert the complete support (Figure 5-18, page 5-25) into the analyzer and attach with the two allen screws (see Figure 5-15, page 5-23).

5. Reconnect all gas lines to the fittings (see Figure 5-15, page 5-23 and Figure 5-17, page 5-24). Be careful not to interchange gas inlets and gas outlets.

6. Reconnect all electrical connections between OXS and BKS, connectors X5 and X7 (see Section 5-5a, page 5-

29).

7. Perform a leak check in accordance with Sections 2-3 (page 2-11) and 6-2 (page 5-6) and calibrate the sensor in accordance with Section 5-4m (page 5-27).

Oxygen Measurement combined with Infrared Channel:

1. Put the fitting with the new sensor onto the support. Position to the stop and fasten with the two screws (see Figure 5-18, page 5-25).

2. Connect the cable from the sensor to P2 of OXS PCB (see Figure 5-16, page 5-24).

3. Perform a leak check in accordance with Sections 2-3 (page 2-11) and 6-2 (page 5-6).

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Instruction Manual

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April 2002

m. Basic Calibration for the Oxygen Sen-

sor

1. Admit ambient air to the analyzer of about 21% O

2. On the OXS PCB (Figure 5-19, page 5-27), Connect the DVM to the following measuring points:

3. TP1 (signal) and TP2 (gnd) of the OXS PCB, mounted directly at the connection block.

Figure 5-19. OXS PCB Location of Measuring Points and Voltage Adjustment

and switch on.

TP1

Potentiometer R4

TP2

4. Set the voltage to 1000 mV (± 5 mV) with potentiometer R4 on the OXS circuit board. setting again!

5. Switch off the analyzer and install the cover. Return the analyzer to the explosion proof housing.

6. Perform a complete zero and span calibration after a sensor replacement.

Do not change this

n. Sample Pump Maintenance

The optional built-in sample pump requires regular replacement of the diaphragm. The replacement interval is determined by the constituents in the sample gas which can vary with different applications. Under normal use, the diaphragm should be replaced every six months.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 5-27

It is recommended that the diaphragm be checked after the first three months of operation to determine the optimum replacement frequency. If no deterioration is noticed, check every three additional months to determine the best replacement frequency.

Instruction Manual

748441-D April 2002

Model CAT100

o. Replacing the EPROM

1. It may be necessary to replace the EPROM if it becomes faulty or if a change to the internal program is necessary or desired.

2. Remove the analyzer from the enclosure (see Section 5-2a, page 5-3)

3. Remove the analyzer cover (see Section 5-4b, page 5-16)

4. On the BKS circuit board (Figure 5-20, page 5-28):

a. Remove jumper J7. b. Note the orientation of the

EPROM in the socket. Remove the EPROM from its socket at D30, being careful not to damage it.

c. If the Pressure Sensor option

(BAF 01) is installed, the EPROM is located on the BAF circuit board.

d. Correctly orient the new EPROM

with respect to the socket before re-insertion. The EPROM is inserted correctly if the half-moon mark is facing the front panel of the analyzer as shown in Figure 5-20, page 5-28.

e. Reconnect the jumper J7.

5. Reconnect that analyzer to the power source and switch it on. The display will chow a flashing “batt.”

6. All data will have been restored to default values. All user and application data, such as system parameters, limits, etc., must now be re-entered.

7. A complete re-calibration of the analyzer (see Section 3-4, page 3-12) must be performed after an EPROM replacement.

X16

BAF 01

Figure 5-20. BKS PCB Location of EPROM and

Battery Buffer Jumper (J7)

Front Panel

X18

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Instruction Manual

748441-D

April 2002

5-5 ANALYZER SERVICE

Be sure to observe appropriate safety precautions when working on powered equipment.

All measuring points are measured against ground (X 11, X 28, or X29).

a. Test Points for BKS PC Board

Supply Voltage + 6 V

Test Point: X 14

Test Device: DVM

Signal: + 6 V DC (+10/-200 mV)

(Adjust with potentiometer R90 if necessary)

Failure: No signal

Possible reasons:

Voltage supply absent Voltage supply < 9 V or

polarity reversed. BKS PCB faulty

Reference Voltage Positive

Test Point: X 10 Test Device: DVM Signal:

+ 5.535 V DC (± 60 mV)

Reference Voltage Negative

Test Point: X 12 Test Device: DVM Signal: Inverse of reference

Voltage positive

The difference between the negative and positive reference voltage must be no more than 10 mV (U

ref+

+ U If the difference is larger, replace the BKS PCB.

≤ ±10 mV)!

ref-

X16 X18

X14

X28 X29

X10 X12

X11

X27

X25

LB1

Front Panel

Figure 5-21. BKS PCB Test Points

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Instruction Manual

748441-D April 2002

Motor Drive (IR Channel only)

Test Point: X 12

Test Device: Oscilloscope

Signal:

Failure: No signal or incorrect

Possible reasons:

Square wave U=6 V

0.3 V) Frequency = 1152 Hz (± 20 Hz)

frequency

Internal 6 V DC absent µP not working. Check if EPROM is in-

serted correctly, perform a reset or replace BKS PCB

P-P

(±

Model CAT100

Temperature Sensor

Test Point: X 8 Test Device: DVM Signal:

Failure: Signal > + 3.5 V DC Possible reasons (IR measurement or

paramagnetic oxygen measurement):

Possible reasons (electrochemical oxygen measurement):

≈ 0 ± 500 mV DC (at ambient temperature)

Temperature sensor not connected

Temperature sensor faulty (replace sensor)

Broken cable on sensor (replace sensor)

BKS PCB faulty (replace BKS)

Temperature sensor not connected

OXS PCB faulty (replace OXS) BKS PCB faulty (replace BKS)

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Model CAT100

Light Barrier Signal

Test Point: Plug 9, pin 2 Test Device: Oscilloscope Signal:

Failure: No signal Possible reasons (IR measureme nt): Chopper not connected

Possible reasons (oxygen measurement without infrared channel):

Analog Preamplifier (paramagnetic oxygen measurement)

Square wave U=6 V

0.3 V) Frequency = 24 Hz (± 0.1 Hz)

Chopper inoperative (switch analyzer off and then on again)

Broken cable to light barrier or faulty light barrier (replace chopper)

BKS PCB faulty (replace BKS)

Solder bridge LB 18 not closed

BKS PCB faulty (replace BKS)

P-P

(±

Instruction Manual

748441-D

April 2002

Test Point: X 25 channel 1 Test Device: DVM Signal:

Failure:

Possible reasons:

At zero gas purge: 0 V DC (± 50 mV)

At ambient air (21% O 500 mV DC (± 50 mV)

No signal or incorrect measuring values

Oxygen sensor not connected Oxygen senso r faulty (replace sensor)

BKS PCB faulty (replace BKS)

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Instruction Manual

748441-D April 2002

Analog Preamplifier (IR measurement)

Model CAT100

Test Point:

Test Device: DVM Signal:

Failure:

Possible reasons:

X 25 channel 1 (analyzer without oxygen measurement)

X27 channel 2

At zero gas purge: 0 V DC (± 100 mV)

There should be a minimum difference of 600 mV (measuring range <1000 ppm: difference 500 mV) between zero point voltage and sensitivity voltage.

No signal or incorrect measuring values

Detector sensor not connected

Detector sensor faulty (replace detector)

BKS PCB faulty (replace BKS)

5-32 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

Emerson Rosemount Analytical CAT 100 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF DRAWINGS

LIST OF TABLES

PREFACE

DEFINITIONS

INTENDED USE STATEMENT

SAFETY SUMMARY

AUTHORIZED PERSONNEL

DOCUMENTATION

COMPLIANCES

DESCRIPTION AND SPECIFICATIONS

1-1 OVERVIEW

1-2 TYPICAL APPLICATIONS

1-3 DETECTOR METHODOLOGIES

a. Non-Dispersive Infrared (NDIR)

b. Paramagnetic Oxygen Method

c. Electrochemical Oxygen Method

d. Thermal Conductivity Method

1-4 SPECIFICATIONS

a. General

b. CAT 100 Detector

2-2 INSTALLATION

2-3 ANALYTICAL LEAK CHECK

OPERATION

3-1 STARTUP PROCEDURE

3-2 TOUCHPAD

a. Overview

b. Elements

c. Actuator Tool

d. Operation

e. Functions

f. FUNCTION Touch pad

g. ENTER Touch pad

3-3 ENTRY OF SYSTEM PARAMETERS

3-4 CALIBRATION

3-5 MANUAL CALIBRATION

3-6 AUTOMATIC CALIBRATION (OPTION)

3-7 CONCENTRATION LIMITS

3-8 MEASUREMENT

3-9 SHUT DOWN

SERIAL INTERFACE OPTION

4-1 OVERVIEW

4-2 PROTOCOLS

4-3 SETTING INTERFACE PARAMETERS

4-4 STRING SYNTAX

4-5 INSTRUCTION (RECEIVE) SYNTAX

MAINTENANCE AND SERVICE

5-1 OVERVIEW

5-2 COMPONENT REMOVAL

5-4 MAINTENANCE

5-5 ANALYZER SERVICE