Emerson Rosemount Analytical CAT 100 Instruction Manual
Instruction Manual
748441-D
May 2004
Model CAT 100
Continuous Analyzer Transmitter
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them
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.
st
1
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
Instruction Manual
748441-D
April 2002
TABLE OF CONTENTS
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
Rosemount Analytical Inc. A Division of Emerson Process Management Contents i
Instruction Manual
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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
Instruction Manual
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April 2002
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
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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.
748441-D
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
9
6
C
US
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
T4
2
T4
2
T4
2
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
N
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)
2
) Propane (C3H8) Butane (C4H10)
2H4
6H14
Some standard industry applications include:
Petrochemical Refinery
•
Light Naphtha Isomerization
H
, CO and CO2 in make-up Hydrogen
2
Gas to Combined Feed
H
in Scrubber Off Gas to Refinery Fuel
2
Gas Header
•
Catalytic Reforming
in Recycle Gas from Product Separa-
H
2
tor
H
in Net Gas from Net Gas Knockout
2
Drum
H
in CCR Nitrogen Header
2
H
in Surge Hopper Vent
2
•
Fluidized Catalytic Cracking
CO and O
Monitoring of Fluidized Cata-
2
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.
2
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)
2
) Water Vapor (H2O) Oxygen (O2)
Propylene in Feed to Sulfur Recovery
Plant
Petrochemical Complex
Ethylene in Primary and Secondary DeMethanizer Overhead
CO
in Ethane-Ethylene Splitter
2
Propylene in Splitter Bottoms
Ammonia and Urea
, CO and CO2 in Synthesis Gas
H
2
Utilities
in Cooling Gas in Turbine Generators
H
2
Continuous Emission Monitoring Systems
(CEMS)
Metals
in Endothermic Furnace
H
2
All Applications
Continuous Emission Monitoring Systems
(CEMS)
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
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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,
2
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
2
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
A
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
CO
2
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
A
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
).
2
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
2
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
A
r
r
A
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
3
, 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
r
A
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-
2
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
2
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
A
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
90
thickness of the Teflon membrane.
The electric current between the electrodes is proportional to the O
concentra-
2
tion in the sample gas being measured.
The resultant signal is measured as a
voltage across the resistor and thermistor,
the latter of which is use d for temperature
compensation. A change in the output
voltage (mV) represents oxygen concentration.
NOTE
The electrochemical O
cell requires a
2
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
2
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
2
Black
Resistor (6
O → 2PbO + 4 H + 4 e
2
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
2
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.
2
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
B
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
2,3
2,3
2,3
Linearity
Zero Drift
Span Drift
Repeatability
Response Time
2,3
NDIR
≤1% ≤1% ≤1% ≤2%
O
2
Paramagnetic
1
O
2
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
4
<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
5
≤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
≤
1%
7
≤5%
≤
1%
Anodized Alum,
Stainless Steel
(gold coated),
BaF
, CaF2
2
15 to 50 Min
≤
1%
≤1%
≤
1%
Stainless Steel,
Platinum, Glass,
PTFE, PVDF,
FPM, Epoxy
resin (Solvent
resistant: no
FPM, no epoxy
but Nickel, Kal-
rez)
4
50 Min 15 to 50 Min 50 Min
≤
1%
≤2%
≤
1%
Aluminum,
Stainless Steel,
FPM, Gold &
ABS,
Teflon
Stainless Steel/
Hastelloy/Glass
≤
1%
≤5%
≤
2%
Glass;
Glass;
7
1
Thermostatically controlled cell 55 °C.
2
Related to full scale, per 10 K.
3
At constant pressure and temperature.
4
Dependent on sensor.
5
Related to measuring valu e.
6
With optional temperature stabilization.
7
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
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.
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)
V1
Channel 2
(option)
V2
V3
V4
Gas Sampling Pump
Throttle and Safety Filter
Channel 1
(option)
(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
[
]
[
]
[
A
[
[
[
]
[
]
[
A
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
D
C
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
MM
Model CAT100
3.00
76.2]
2.90
[73.7]
B
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
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