Ge TMO2D-TC User Manual
May 2003
Process Control Instruments
Model TMO2D-TC
Thermal Conductivity Analyzer
User’s Manual 910-146A2
May 2003
TMO2-TC Thermal Conductivity Transmitter with TMO2D
iii
May 2003
Warranty Each instrument manufactured by GE Panametrics is warranted to be
free from defects in material and workmanship. Liability under this
warranty is limited to restoring the instrument to normal operation or
replacing the instrument, at the sole discretion of GE Panametrics. Fuses
and batteries are specifically excluded from any liability. This warranty
is effective from the date of delivery to the original purchaser. If GE
Panametrics determines that the equipment was defective, the warranty
period is:
• one year for general electronic failures of the instrument
• one year for mechanical failures of the transducers
If GE Panametrics determines that the equipment was damaged by
misuse, improper installation, the use of unauthorized replacement parts,
or operating conditions outside the guidelines specified by GE
Panametrics, the repairs are not covered under this warranty.
The warranties set forth herein are exclusive and are in lieu of
all other warranties whether statutory, express or implied
(including warranties or merchantability and fitness for a
particular purpose, and warranties arising from course of
dealing or usage or trade).
Return Policy If a GE Panametrics instrument malfunctions within the warranty period,
the following procedure must be completed:
1. Notify GE Panametrics, giving full details of the problem, and
provide the model number and serial number of the instrument. If the
nature of the problem indicates the need for factory service, GE
Panametrics will issue a RETURN AUTHORIZATION NUMBER
(RAN), and shipping instructions for the return of the instrument to a
service center will be provided.
2. If GE Panametrics instructs you to send your instrument to a service
center, it must be shipped prepaid to the authorized repair station
indicated in the shipping instructions.
3. Upon receipt, GE Panametrics will evaluate the instrument to
determine the cause of the malfunction.
Then, one of the following courses of action will then be taken:
• If the damage is covered under the terms of the warranty, the
instrument will be repaired at no cost to the owner and returned.
• If GE Panametrics determines that the damage is not covered under
the terms of the warranty, or if the warranty has expired, an estimate
for the cost of the repairs at standard rates will be provided. Upon
receipt of the owner’s approval to proceed, the instrument will be
repaired and returned.
iv
May 2003
Table of Contents
Chapter 1: Features and Capabilities
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
TMO2-TC Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Sample System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
TMO2D-TC Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Extra Cable (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Chapter 2: Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Mounting the TMO2-TC Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Mounting the Sample System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Manual, 2-Port (Sealed Reference Gas) Sample System . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Manual, 4-Port (Flowing Reference Gas) Sample System . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Automatic, 2-Port (Sealed Reference Gas) Sample System . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Mounting the TMO2D-TC Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Wiring the TMO2-TC Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Wiring the TMO2D-TC Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Chapter 3: Operation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Powering Up the TMO2D-TC Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Establishing a Flow of Sample Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Operating the TMO2D-TC Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Chapter 4: Programming
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Entering Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
The Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
The Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
The Recorders Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
The Alarms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
The Tests Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
The Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
v
May 2003
Table of Contents (cont.)
Chapter 5: Calibration
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Preparing the Transmitter for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
2-Port (Sealed Reference Gas) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
4-Port (Flowing Reference Gas) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Checking/Changing Switch and Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Chapter 6: Specifications
TMO2-TC Transmitter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
TMO2D-TC Display Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Chapter 7: Ordering Information
Appendix A: Relative Thermal Conductivity of Common Gases
Appendix B: Applications
H2 in N2 in Heat Treat Furnace Atmospheres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Basic Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Permanent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Detailed Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
H2 Purity in H2 Electricity Generator Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Basic Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
How Previously Handled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Permanent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Detailed Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
vi
May 2003
Table of Contents (cont.)
Appendix C: Installation and Maintenance Drawings
Appendix D: Menu Flow Diagrams
Appendix E: Special Programming
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Entering the Hidden Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Select Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
LabCal Recorders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Manual Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Erase RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Appendix F: Calibration Procedure and Adjustment Locations for Older Versions
Calibration Procedure for PCB #703-1036 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
2-Port (Sealed Reference Gas) Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
4-Port (Flowing Reference Gas) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Checking/Changing Switch and Jumper Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-6
Calibration Procedure for PCB #703-867 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-7
2-Port (Sealed Reference Gas) Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-7
4-Port (Flowing Reference Gas) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
Appendix G: Sample TMO2D-TC Calibration Sheet
Appendix H: Installation Instructions for CE Mark Compliance
Installation Instructions for CE Mark Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
vii
Chapter 1
Features and Capabilities
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Typical Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
May 2003
Overview This chapter will introduce you to the features and capabilities of the
GE Panametrics TMO2D-TC Thermal Conductivity Analyzer. You
will find the following topics discussed:
• Introduction — A discussion of the TMO2D-TC Analyzer features
and capabilities.
• Theory of Operation — Details on TMO2-TC Transmitter
construction and how the measurement is made.
• System Description — A detailed description of the basic
TMO2D-TC Analyzer and available options, and sample systems.
• Typical Applications — A brief discussion of industries and
applications where the TMO2D-TC can be used, along with two
common applications and the required TMO2D-TC
configurations.
TMO2D-TC technical specifications can be found in Chapter 6,
Specifications. Ordering information can be found in Chapter 7,
Ordering Information.
Introduction The GE Panametrics TMO2D-TC is an analyzer that measures the
thermal conductivity of a binary (or pseudo-binary) gas mixture,
determines and displays the concentration of one of the gases in the
mixture, and also provides 0/4-20 mA and RS232C outputs and alarm
relays for process control requirements. The TMO2D-TC consists of
two main components — the TMO2-TC Transmitter and the
TMO2D-TC Display.
The TMO2-TC Transmitter offers several unique design features:
• Ultra-stable thermistors and a temperature-controlled measuring
cell (55
span stability, as well as insensitivity to ambient temperature
variations.
o
C standard, or 70 oC optional) provide excellent zero and
• The measuring cell design makes it resistant to contamination and
essentially flow insensitive. Since it has no moving parts, the
transmitter can handle the shock and vibration found in many
industrial applications.
• You can select a 2-port version for measurement of zero-based gas
mixtures using a sealed reference gas (air), or 4-port version for
measurement of zero-suppressed gas mixtures (and some other
special calibrations) using a flowing reference gas.
Features and Capabilities 1-1
11/1/95
Introduction (cont.) • The TMO2-TC modular construction means that the unit can be
field-calibrated quickly and easily; or the plug-in measuring cell
can be replaced with a pre-calibrated spare in minutes.
• The TMO2-TC Transmitter, with weatherproof and explosion-
proof packaging, is designed to be installed as close as possible to
the process sample point. It can be located up to 2,800 feet (850
meters) from the TMO2D-TC Display using inexpensive,
unshielded cable.
The TMO2D-TC Display offers several advanced features:
• The microprocessor-based TMO2D-TC electronics unit features a
two-line, backlit LCD display, full keypad, and menu-driven
software to provide easy access to a variety of features, including
user-selectable gas range, recorder output range, alarm settings,
and automatic calibration (Auto Cal).
• Standard 0/4-20 mA output and dual Form C alarm relays, coupled
with optional dual isolated 0/4-20 mA outputs and dual relays for
Auto Cal, provide excellent flexibility for process control
applications.
• Long-term, hands-off performance is provided by Auto Cal. When
re calibration is desired, the TMO2D-TC controls solenoid valves
in the sample system to bring zero and span gases to the TMO2-TC
Transmitter. Then, TMO2D-TC software compares the Auto Cal
readings with factory calibration data and makes any necessary
corrections -automatically - so manual re calibration requirements
can be reduced significantly.
• The TMO2D-TC Display, with bench, rack, panel, weatherproof,
and explosion-proof packaging options, can be located adjacent to
the TMO2-TC Transmitter, or up to 2,800 feet (850 meters) away
using inexpensive, unshielded cable.
1-2 Features and Capabilities
11/1/95
Theory of Operation The TMO2-TC Transmitter measures the concentration of a gas in a
binary gas mixture by measuring the thermal conductivity of the
sample gas and comparing it to the thermal conductivity of a selected
reference gas.
Two ultra-stable, glass-coated thermistors are used: one in contact
with the sample gas, and the other in contact with a selected reference
gas. The thermistors are mounted so that they are in close proximity
to the stainless steel walls of the sample chamber. The entire sensor is
o
heated to 55
sensor temperature using a constant current source. The thermistors
lose heat to the walls of the sample chamber at a rate that is
proportional to the thermal conductivity of the gas surrounding them.
Thus, each thermistor will reach a different equilibrium temperature.
The temperature difference between the two thermistors is detected in
an electrical bridge circuit. It is amplified and converted to a 4-20 mA
output proportional to the concentration of one of the constituents of
the binary gas mixture.
C (or 70 oC) and the thermistors are heated above the
Appendix A contains a Table of Relative Thermal Conductivity of
Common Gases. Figure 1-1 on the next page shows several of these
values graphically. In order to measure 0 to 25% H
in N2, the
2
reference gas would be air (2-port version, sealed reference gas), and,
for calibration, the zero gas would be 100% N
span gas 25% H
, the reference gas would be 100% H2 (4-port version, flowing
N
2
(balance N2). In order to measure 90-100% H2 in
2
reference gas), the zero gas would be 90% H
span gas 100% H
(the same as the reference gas).
2
(i.e., 0 % H2) and the
2
(balance N2), and the
2
The TMO2-TC has a polarity adjustment switch which permits the
measurement of gases (such as CO
) with relative thermal
2
conductivity less than the background gas.
Features and Capabilities 1-3
11/1/95
Theory of Operation
(cont.)
Air/N
2
SO
CO
2
C4-C
6
2
CH4Ne
He
H
2
Figure 1-1: Relative Thermal Conductivity of Several Common Gases
1-4 Features and Capabilities
May 2003
System Description The basic TMO2D-TC measurement system consists of a TMO2-TC
Transmitter mounted in a sample system and connected to a TMO2DTC Display. The sample system is mandatory, and can be provided by
GE Panametrics or constructed according to our recommendations.
The TMO2D-TC is supplied with a standard 10 ft. (3 m), 3-wire cable
for connecting the transmitter to the display module. Lengths up to
2,800 ft. (850 m) are optionally available.
TMO2-TC Transmitter The TMO2-TC Transmitter is self-contained, consisting of the
thermal conductivity sensor and associated electronics. It requires 24
VDC power (1 amp maximum at power-up), which it receives from
the TMO2D-TC Display. It provides a 4-20 mA output signal to the
display module proportional to the thermal conductivity of the sample
gas and to the concentration of one of the gases in the binary mixture.
The TMO2-TC is designed to be installed in a sample system as close
as possible to the process sample point. Thus, it is available in two
environmental packages — weatherproof (NEMA-4X; IP65) and
explosion-proof (Class I, Groups C,D, Div. 1; Cenelec EEx d II C T6)
with the addition of flame arrestors to the sample/reference gas inlet
and outlet.
Each environmental package is available in a standard 2-port (sealed
reference gas) version, or optional 4-port (flowing reference gas)
version.
Features and Capabilities 1-5
11/1/95
2-Port (Sealed Reference Gas) Version
This standard configuration (see Figure 1-2 below) is used for zerobased ranges with air or nitrogen at atmospheric pressure as the
balance or background gas. It utilizes air with desiccant in a factorysealed chamber as the reference gas. The following standard ranges
and gases are provided:
0 to 1%
0 to 2%
0 to 5%
0 to 10%
0 to 25%
0 to 50%
0 to 100%
in N
H
2
2
CO2 in N2 (minimum range 0 to 5% CO2)|
in Air (minimum range 0 to 5% CO2)
CO
2
He in N
He in Air
2
Figure 1-2: 2-Port (Sealed Reference Gas) TMO2-TC
1-6 Features and Capabilities
11/1/95
4-Port (Flowing Reference Gas) Version
This optional configuration (see Figure 1-3 on the following page) is
used for zero-suppressed ranges and some other special applications.
Typically, a flowing reference gas of 100% H
following standard ranges and gases are provided:
90 to 100%
80 to 100%
in N
H
2
2
CO2 in N2/Air
He in N
2
/Air
Note: For factory calibration pricing on the standard ranges and
gases, or for pricing on other zero-suppressed ranges and
gases, please consult the factory.
The TMO2-TC is supplied with a standard measurement cell
o
operating temperature of 55
C. An optional 70 oC cell operating
temperature is available.
or CO2 is used. The
2
Note: The 70
high temperature applications, since it will result in reduced
sensitivity.
o
C operating temperature should be selected only for
Features and Capabilities 1-7
11/1/95
4-Port (Flowing Reference Gas) Version (cont.)
Top View
Bottom View
Figure 1-3: 4-Port (Flowing Reference Gas) TMO2-TC
1-8 Features and Capabilities
May 2003
Sample System A sample system is mandatory for use with the TMO2-TC. The
design of the sample system will depend on the conditions of the
sample gas and the requirements of the application. In general, a
sample system must deliver a clean, representative sample to the
TMO2-TC at a temperature, pressure, and flow rate that are within
acceptable limits. Standard TMO2-TC sample conditions are as
follows:
• Less than 50
temperature)
o
C (122 oF) temperature (for 55 oC cell operating
• Atmospheric pressure
• 0.5 SCFH (250 cc/min) flow rate
GE Panametrics offers sample systems for a wide variety of
applications. Three standard sample systems for the TMO2-TC are
shown in Chapter 2, Installation. For assistance in designing your
own sample system, please consult the factory.
TMO2D-TC Display The TMO2D-TC Display receives a 4-20 mA signal from the TMO2-
TC Transmitter proportional to the concentration of one of the gases
in the binary mixture (the sample gas). It then displays the
concentration (and other information) on a 2-line x 24 character,
backlit LCD.
It requires 100/120/220/240 VAC power (35 watts max.), and
provides 24 VDC power to the TMO2-TC Transmitter. The standard
TMO2D-TC provides a 0/4-20 mA analog output; an RS232C digital
output; and dual Form C, SPDT relays for process monitoring and
control. Dual isolated 0/4-20 mA outputs and a second pair of relays
for Auto Cal are available as options.
The TMO2D-TC can be located adjacent to the TMO2-TC
Transmitter or as far as 2,800 ft. (850 m) away. It is provided in
bench, rack, panel, weatherproof (NEMA 4X; IP65), or explosionproof mounting configurations. The standard TMO2D-TC is suitable
for use in general purpose areas. A package suitable for use in Class I,
Div. 2 hazardous areas is available as an option. This package
includes hermetically-sealed alarm relays.
Extra Cable (optional) GE Panametrics provides a 10 ft. (3 m) length of 3-wire, color-coded
cable with each TMO2D-TC to connect the transmitter to the display
module. The same cable is available in lengths up to 2,800 ft (850 m).
If you are using your own cable, refer to Chapter 2, Table 2-2, Cable
Requirements, for recommendations.
Features and Capabilities 1-9
11/1/95
Typical Applications The TMO2D-TC can be used in a wide variety of industrial
applications where it is necessary to measure the concentration of one
component of a binary gas mixture. It can also be used in pseudobinary gas mixtures where the ratio of concentrations of the
background gas components remains constant, and in gaseous
mixtures where the thermal conductivity of the gas of interest is
significantly different from that of the background gas. Some typical
industries and applications include:
• Metals Industry —
H
in heat treat furnace atmospheres
2
• Electric Power Industry —
in generator cooling systems
H
2
• Gas Production Industry —
Purity monitoring of argon, hydrogen, nitrogen, helium
• Chemical Industry —
in ammonia synthesis gas
H
2
H
in methanol synthesis gas
2
in chlorine plants
H
2
• Food Industry —
CO
in fermentation processes
2
Ethylene Oxide (ETO) sterilization
• Steel Industry —
in blast furnace top gas
H
2
• Petroleum Industry —
in hydrocarbon streams
H
2
Two very common applications are as follows:
in N2 in heat treat furnace atmospheres - Zero-based 0-25%
1. H
2
, 2-Port (sealed reference gas, air)
H
2
purity in H2 electricity generator cooling - Zero-suppressed,
2. H
2
80-100% H
For more details on these applications, refer to Appendix B,
Applications. For details on applications not shown in Appendix B, or
if you wish to discuss your own application, please consult the
factory.
, 4-Port (flowing reference gas, 100% H2)
2
1-10 Features and Capabilities
Chapter 2
Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Mounting the TMO2-TC Transmitter . . . . . . . . . . . . . . . . . . . . . . . .2-2
Mounting the Sample System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Mounting the TMO2D-TC Display . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Wiring the TMO2-TC Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Wiring the TMO2D-TC Display . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
May 2003
Overview This chapter will describe how to mount and wire the TMO2-TC
Transmitter and its sample system, and the TMO2D-TC Display. You
will find the following topics discussed:
• Introduction — A brief discussion of installation steps.
• Mounting the TMO2-TC Transmitter — How to mount the
transmitter in a sample system.
• Mounting the Sample System — Mounting and plumbing a GE
Panametrics sample system. Includes drawings of basic 2-Port and
4-Port sample systems, and an automatic 2-Port sample system.
• Mounting the TMO2D-TC Display — How to mount the different
TMO2D-TC packaging configurations.
• Wiring the TMO2-TC Transmitter — How to connect the
transmitter to the display module.
• Wiring the TMO2D-TC Display — Connecting 100/120/220/240
VAC power, 0/4-20 mA output and alarm relay wiring to the
TMO2D-TC.
!WARNING!
TO ENSURE THE SAFE OPERATION OF THE
TMO2D-TC, YOU MUST INSTALL AND OPERATE IT
AS DESCRIBED IN THIS MANUAL. IN ADDITION, BE
SURE TO FOLLOW ALL APPLICABLE SAFETY
CODES AND REGULATIONS FOR INSTALLING
ELECTRICAL EQUIPMENT IN YOUR AREA.
PROCEDURES SHOULD BE PERFORMED BY
TRAINED SERVICE PERSONNEL.
!ATTENTION EUROPEAN CUSTOMERS!
IN ORDER TO MEET CE MARK REQUIREMENTS,
YOU MUST INSTALL CABLES AS DESCRIBED IN
APPENDIX H.
Note: Different versions of the TMO2D-TC display have different
PC boards. In Appendix C refer to the appropriate drawings,
as follows:
• Serial numbers 101 through 749, schematic 700-997 and
PCB assembly drawing 703-997.
• Serial numbers 750 or greater, schematics 700-1226 and
PCB assembly drawing 703-1226.
Installation 2-1
May 2003
Introduction Installation of the TMO2D-TC analyzer typically consists of five
steps:
1. Mounting the TMO2-TC Transmitter in a sample system. (If you
purchased your sample system from GE Panametrics, this step has
already been done for you.)
2. Mounting, plumbing (and possibly wiring) the sample system.
3. Mounting the TMO2D-TC Display.
4. Making wiring connections between the transmitter and the
display module.
5. Making wiring connections to the TMO2D-TC Display for power,
outputs, and alarms.
Mounting the TMO2-TC Transmitter
This section applies only if you are mounting the TMO2-TC
Transmitter to a sample system that has not been supplied by GE
Panametrics.
Your sample system should deliver a clean, representative sample to
the TMO2-TC at the proper temperature, pressure and flow rate. This
usually means a clean, dry sample (free of solid and liquid
particulates) at atmospheric pressure; a temperature no greater than
o
C (122 oF); and a flow rate of approximately 0.5 SCFH (250 cc/
50
min). Factory calibration of the sensor is at atmospheric pressure and
0.5 SCFH - higher or lower operating pressures may necessitate field-
calibration adjustment.
A simple sample system for a 2-Port TMO2-TC might have an inlet
and/or outlet flow regulating needle valve; a flow meter; and a
pressure gauge, in addition to the TMO2-TC Transmitter.
The TMO2-TC Transmitter should be mounted in the sample system
o
so that it is upright and level to within +/- 15
. Also, provide at least
9" of clearance above the top cover of the transmitter to allow access
to the transmitter printed circuit board (PCB) for calibration and
maintenance. For a 2-Port TMO2-TC, connect the sample system
Sample Inlet and Sample Outlet portions to the appropriate TMO2TC port (see Drawing 712-225 in Appendix C for port location). For a
4-Port system, also connect the Reference Inlet and Reference Outlet
portions to the appropriate TMO2-TC port (see Drawing 712-226 in
Appendix C for port location).
!WARNING!
FOR EXPLOSION-PROOF UNITS, BE SURE TO
CONFORM TO ALL SAFETY AND ELECTRICAL
CODE REQUIREMENTS.
2-2 Installation
May 2003
Mounting the Sample System
Manual, 2-Port (Sealed Reference Gas) Sample System
You can order a complete sample system, which includes the TMO2TC Transmitter and all necessary components and sample tubing
mounted on a metal panel, from GE Panametrics. Several standard
sample systems are available; and custom-designed sample systems
can be built to your exact specifications. Following are descriptions
of three standard sample systems:
Figure 2-1 below shows a basic sample system for a 2-Port (sealed
reference gas) TMO2-TC. This sample system consists of inlet needle
valves for sample, zero, and span gases; a ball valve; a 2-port TMO2TC; a pressure gauge; and a flow meter. All components are mounted
on a painted steel plate. Other components could be added for
filtration (filter/coalescer), pressure control (regulator), or flow
control (pump).
Figure 2-1: Basic Sample System for a 2-Port TMO2-TC
Installation 2-3
May 2003
Manual, 4-Port (Flowing Reference Gas) Sample System
Figure 2-2 below shows a basic sample system for a 4-Port (flowing
reference gas) TMO2-TC. This sample system consists of inlet needle
valves for sample, reference, and calibration gases; a 4-port TMO2TC; two pressure gauges; and two flow meters. All components are
mounted on a painted steel plate. Other components could be added
for filtration (filter/coalescer), pressure control (regulator), or flow
control (pump).
Figure 2-2: Basic Sample System for a 4-Port TMO2-TC
2-4 Installation
11/1/95
Automatic, 2-Port (Sealed Reference Gas) Sample System
Figure 2-3 below shows an automatic sample system for a 2-Port
(sealed reference gas) TMO2-TC. This sample system requires the
Auto Cal option on the TMO2D-TC Display. It consists of inlet
needle valves for sample, zero, span, and optional calibration gases;
two electrically-actuated solenoid valves for gas selection; a 2-Port
TMO2-TC; a pressure gauge; a flowmeter; a regulating needle valve;
and a sample pump. All components are mounted on a painted steel
plate. Other components could be added for filtration (filter/
coalescer), or pressure control (regulator).
Figure 2-3: Automatic Sample System
for a 2-Port TMO2-TC
Installation 2-5
May 2003
Automatic, 2-Port
(Sealed Reference Gas)
Sample System (cont.)
Mounting the TMO2DTC Display
When used in conjunction with the TMO2D-TC Display with the
Auto Cal option, the above sample system allows automatic
switching of sample, zero, and span gases during calibration. Refer to
Appendix B, Applications, for details on sample systems designed by
GE Panametrics for specific applications.
Mount the sample system as close as possible to the process sample
point. Once the sample system is mounted, connect all inlet and outlet
lines via the fittings on the sample system (1/4" compression). The
sample line leading from the process to the sample system should be
of 1/4" stainless steel tubing, and as short as possible in order to
insure a representative sample.
The TMO2D-TC Display is available in five mounting
configurations: bench, rack, panel, weatherproof, and explosionproof. See Appendix C, Outline and Installation Drawings, for
dimensional drawings for each configuration, as well as rack/panel
cutout dimensions.
No special mounting requirements are needed for the TMO2D-TC
Display.
!WARNING!
FOR EXPLOSION-PROOF AND CLASS I, DIV. 2
UNITS, BE SURE TO CONFORM TO ALL SAFETY
AND ELECTRICAL CODE REQUIREMENTS.
!WARNING!
TO ENSURE THE SAFE OPERATION OF THE
TMO2D-TC, YOU MUST INSTALL AND OPERATE IT
AS DESCRIBED IN THIS MANUAL. IN ADDITION, BE
SURE TO FOLLOW ALL APPLICABLE SAFETY
CODES AND REGULATIONS FOR INSTALLING
ELECTRICAL EQUIPMENT IN YOUR AREA.
PROCEDURES SHOULD BE PERFORMED BY
TRAINED SERVICE PERSONNEL.
2-6 Installation
1/20/97
Wiring the TMO2-TC Transmitter
Caution!
Always bring power to the TMO2-TC immediately after
installation, especially when it is mounted outdoors or in
a humid area.
This section describes how to wire the TMO2-TC Transmitter to the
TMO2D-TC Display. First, the transmitter enclosure must be
grounded. This can be done using an external ground screw on the
TMO2-TC, or, if required, an internal ground screw located below the
transmitter PCB. See Figure 2-4 below for the location of both ground
screws.
Figure 2-4: Location of Ground Screws
= Protective Conductor Terminal
Internal
Ground
Screw
External
Ground
Screw
Installation 2-7
11/1/95
Wiring the TMO2-TC
Transmitter (cont.)
Wiring connections to the TMO2-TC Transmitter are made to
terminal block TB1, which is accessed by removing the TMO2-TC
cover. See Figure 2-5 below for the location and pin designations for
TB1. Also refer to Appendix C, Outline and Installation Drawings.
1
2
3
4
+24 VDC/1Amp
Return
Output Signal
No Connection
1
2
3
4
Red
Blk
Wht
Figure 2-5: TMO2-TC Wiring Connections
Wiring connections to the TMO2D-TC Display are made to the
terminal block labeled OXYGEN CELL at the rear of the TMO2DTC. See Figure 2-6 on the following page for the location of the
OXYGEN CELL terminal block.
Caution!
Do not make any connections to unassigned or unused
terminals.
2-8 Installation
Wiring the TMO2-TC
Transmitter (cont.)
11/1/95
14
32
TMO2-TC
Outlet
TMO2D-TC
OXYGEN
SPARE
Cell
+24V
RTN
REC
REC
B
RECORDERS
INPUTS
COMP
0/4-20 mA
+24V
RTN
REC A REC B
IN2
IN1
OX
+
-
+
_
A
+
_
+
-
AUTOCAL
PROCESS CAL
C NC NO
C NC NO
ALARMS
LOW HIGH
C NC NOC NC NO
Zero
Gas
Span
Gas
Process Gas Inlet
Auto-Calibration System
High
Alarm
Solonoid Valve
Power
Low
Alarm
Alarm
Power
Figure 2-6: TMO2D-TC Wiring Connections
Installation 2-9
May 2003
Wiring the TMO2-TC
Transmitter (cont.)
Table 2-2 below shows the transmitter to display module wiring
connections using the standard GE Panametrics TMO2D-TC cable.
This cable can be used for distances up to 2,800 ft (850 m). If you are
using your own cable, refer to Table 2-2 for cable requirements.
Table 2-1: Cable Requirements
Max Cable Length Cable Size
Sq.
Feet Meters AWG
450 130 22 0.35
700 200 20 0.6
1,050 320 18 1.0
1,700 500 16 1.2
2,800 850 14 2.0
4,000 1,200 12 3.0
Use the following steps to make the proper connections:
Millimeters
1. Route the cable into the transmitter through one of the 3/4"
conduit holes.
!WARNING!
BE SURE TO PLUG UP THE UNUSED CONDUIT
HOLE ON THE SIDE OF THE TRANSMITTER IN
ORDER TO MAINTAIN THE APPROPRIATE
WEATHERPROOF OR EXPLOSION-PROOF
RATING.
2. Unplug TB1 by carefully pulling it directly up without bending the
pins attached to the PCB.
3. Loosen the TB1 side screws and insert the colored wires into the
corresponding openings on top of TB1. See Table 2-1 above for
color-coded pin designations.
!WARNING!
BE SURE THAT +24 VDC (RED WIRE) IS
CONNECTED TO TERMINAL TB1-1. CONNECTING
+24 VDC POWER TO ANY OTHER TERMINAL WILL
DAMAGE THE TMO2-TC PCB, REQUIRING
FACTORY REPAIR.
2-10 Installation
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