Rosemount 1000A GC Hardware Reference 3-9000-750 Rev A Manuals & Guides

Model 1000A

Gas Chromatograph

Hardware Reference Manual

Applies to Both

Daniel Danalyzer Model 1000A

Rosemount Analytical Model 1000A

Part Number 3-9000-750

Revision A

JUNE 2008

Model 1000A Gas Chromatograph

Hardware Reference Manual

NOTICE

DANIEL MEASUREMENT AND CONTROL, INC. AND ROSEMOUNT ANALYTICAL, INC.
(COLLECTIVELY, “SELLER”) SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS IN
THIS MANUAL OR OMISSIONS FROM THIS MANUAL. SELLER MAKES NO WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND, IN NO EVENT,
SHALL SELLER BE LIABLE FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING,
BUT NOT LIMITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, ETC.

PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER IDENTIFICATION
ONLY AND MAY BE TRADEMARKS/REGISTERED TRADEMARKS OF THESE COMPANIES.

THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORMATIONAL PURPOSES
ONLY, AND WHILE EVERY EFFORT HAS BEEN MADE TO ENSURE THEIR ACCURACY, THEY
ARE NOT TO BE CONSTRUED AS WARRANTIES OR GUARANTEES, EXPRESSED OR IMPLIED,
REGARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR
APPLICABILITY. WE RESERVE THE RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR
SPECIFICATIONS OF SUCH PRODUCTS AT ANY TIME.

SELLER DOES NOT ASSUME RESPONSIBILITY FOR THE SELECTION, USE OR MAINTENANCE
OF ANY PRODUCT. RESPONSIBILITY FOR PROPER SELECTION, USE AND MAINTENANCE OF
ANY SELLER PRODUCT REMAINS SOLELY WITH THE PURCHASER AND END-USER.

DANIEL AND THE DANIEL LOGO ARE REGISTERED TRADEMARKS OF DANIEL INDUSTRIES,
INC. THE ROSEMOUNT AND ROSEMOUNT ANALYTICAL LOGO THE ARE REGISTERED
TRADEMARKS OF ROSEMOUNT ANALYTICAL, INC. THE EMERSON LOGO IS A TRADEMARK
AND SERVICE MARK OF EMERSON ELECTRIC CO.

COPYRIGHT

All rights reserved. No part of this work may be reproduced or copied in any form or by any

means - graphic, electronic, or mechanical — without first receiving the written permission of

©

2008 BY DANIEL MEASUREMENT AND CONTROL, INC., HOUSTON, TEXAS,

U.S.A.

Daniel Measurement and Control, Inc. Houston, Texas, U.S.A.

WARRANTY

1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as
otherwise expressly provided herein, Daniel Measurement and Control, Inc. and Rosemount
Analytical, Inc., (collectively“Seller”) warrants that the firmware will execute the programming
instructions provided by Seller, and that the Goods manufactured or Services provided by Seller
will be free from defects in materials or workmanship under normal use and care until the
expiration of the applicable warranty period. Goods are warranted for twelve (12) months from
the date of initial installation or eighteen (18) months from the date of shipment by Seller,
whichever period expires first. Consumables and Services are warranted for a period of 90 days
from the date of shipment or completion of the Services. Products purchased by Seller from a
third party for resale to Buyer ("Resale Products") shall carry only the warranty extended by the
original manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond making
a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If
Buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable
warranty period, Seller shall, at its option, promptly correct any errors that are found by Seller in
the firmware or Services, or repair or replace F.O.B. point of manufacture that portion of the
Goods or firmware found by Seller to be defective, or refund the purchase price of the defective
portion of the Goods/Services. All replacements or repairs necessitated by inadequate
maintenance, normal wear and usage, unsuitable power sources, unsuitable environmental
conditions, accident, misuse, improper installation, modification, repair, storage or handling, or
any other cause not the fault of Seller are not covered by this limited warranty, and shall be at
Buyer's expense. Seller shall not be obligated to pay any costs or charges incurred by Buyer or
any other party except as may be agreed upon in writing in advance by an authorized Seller rep­resentative. All costs of dismantling, reinstallation and freight and the time and expenses of
Seller's personnel for site travel and diagnosis under this warranty clause shall be borne by Buyer
unless accepted in writing by Seller. Goods repaired and parts replaced during the warranty
period shall be in warranty for the remainder of the original warranty period or ninety (90) days,
whichever is longer. This limited warranty is the only warranty made by Seller and can be
amended only in a writing signed by an authorized representative of Seller. Except as otherwise
expressly provided in the Agreement, THERE ARE NO REPRESENTATIONS OR WARRANTIES OF
ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR
PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. It

is understood that corrosion or erosion of materials is not covered by our guarantee.

2.

LIMITATION OF REMEDY AND LIABILITY: SELLER SHALL NOT BE LIABLE FOR DAMAGES
CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF
WARRANTY HEREUNDER SHALL BE LIMITED TO REPAIR, CORRECTION, REPLACEMENT OR
REFUND OF PURCHASE PRICE UNDER THE LIMITED WARRANTY CLAUSE IN SECTION 1
HEREIN. IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION
(WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER
TORT OR OTHERWISE), SHALL SELLER'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS
EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED OR SERVICES
PROVIDED BY SELLER GIVING RISE TO THE CLAIM OR CAUSE OF ACTION. BUYER AGREES
THAT IN NO EVENT SHALL SELLER'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXTEND
TO INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. THE TERM
"CONSEQUENTIAL DAMAGES" SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF
ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE AND COST OF CAPITAL.

IMPORTANT INSTRUCTIONS

• Read all instructions prior to installing, operating, and servicing this product.

• Follow all warnings, cautions, and instructions marked on and supplied with this product.

• Inspect the equipment packing case and if damage exists, notify your local carrier for
liability.

• Open the packing list and carefully remove equipment and spare or replacement parts

from the case. Inspect all equipment for damage and missing parts.

• If items are missing, contact your local Product Services Department representative or

the sales office. Provide the equipment serial number and sales order number to the
Product Services Department or sales representative.

All returned equipment or parts must have an RMA (Returned Materials Authorization)
form obtained from the Products Services Department. Complete the Customer Problem
Report or include a letter describing the problem and corrective action to be performed at
the factory.

Phone: [phone]

• Physically attach the RMA, corrective action documentation, and a copy of the packing

list to the equipment and place inside the shipping case. An envelope with a copy of the
packing list may be attached to the outside of the shipping case. Send to the address
shown above.

• Install equipment as specified per the installation instructions and per applicable local and

national codes. All connections shall be made to proper electrical and pressure sources.

• Ensure that all equipment doors are closed and protective covers are in place, except

when maintenance is being performed by qualified persons, to prevent personal injury.

• Use of this product for any purpose other than its intended purpose may result in property

damage and/or serious injury or death.

• Before opening the flameproof enclosure in a flammable atmosphere, the electrical

circuits must be interrupted.

• Repairs must be performed using only authorized replacement parts as specified by the

manufacturer. Use of unauthorized parts can affect the product's performance and place
the safe operation of the product at risk.

• When installing or servicing ATEX certified units, the ATEX approval applies only to

equipment without cable glands. When mounting the flameproof enclosures in a
hazardous area, only flameproof cable glands certified to IEC 60079-1 must be used.

This page is intentionally left blank.

Model 1000A

DESCRIPTION 1.1 PURPOSE OF THIS MANUAL ..........................1-1

TABLE OF CONTENTS i

TABLE OF CONTENTS

1.2 INTRODUCTION............................................1-2

1.3 FUNCTIONAL DESCRIPTION...........................1-3

1.4 MINIMUM PC REQUIREMENTS .......................1-5

1.5 MODES OF OPERATION.................................1-6

1.5.1 User Interface ...............................................1-6

1.5.2 Capabilities...................................................1-7

1.6 THEORY OF OPERATION ...............................1-8

EQUIPMENT

DESCRIPTION

1.6.1 Analyzer Detector .........................................1-8

1.6.2 Data Acquisition .........................................1-10

1.6.3 Peak Detection ...........................................1-11

1.6.4 Basic Analysis Computations ........................ 1-13

1.7 GLOSSARY ................................................1-16

2.1 SAMPLING SYSTEM......................................2-1

2.1.1 Sampling Point Location.................................2-2

2.1.2 Sample Volume and Flow Rate........................2-2

2.1.3 Sample Conditioning......................................2-3

2.1.4 Contamination Precautions .............................2-3

2.1.5 Valving ........................................................2-3

2.1.6 Calibration Gas .............................................2-3

2.2 ANALYZER...................................................2-4

2.2.1 Physical Description ......................................2-4

2.2.2 Chromatograph Valves...................................2-5

2.2.3 Detector Subsystem ......................................2-6

MAY 2008 DESCRIPTION

ii TABLE OF CONTENTS

Model 1000A

2.2.4 Analyzer Preamplifier Unit ..............................2-6

2.2.5 Analyzer Specifications ..................................2-7

2.2.6 Utility Gas Requirements ................................2-8

2.3 ELECTRONIC ASSEMBLY ...............................2-8

2.3.1 Controller Hardware Configurations ................. 2-8

INSTALLATION AND

SETUP

3.1 PRECAUTIONS AND WARNINGS .................... 3-3

3.1.1 Hazardous Environments ................................3-3

3.1.2 Power Source Wiring .....................................3-4

3.1.3 Signal Wiring ................................................3-5

3.1.4 Electrical and Signal Ground ...........................3-6

3.1.5 Electrical Conduit ..........................................3-8

3.1.6 Sample Systems Requirements .......................3-9

3.2 PREPARATION............................................ 3-10

3.2.1 Introduction................................................ 3-10

3.2.2 Site Selection .............................................3-10

3.2.3 Unpacking the Unit...................................... 3-11

3.2.4 Necessary Tools and Components ................. 3-12

3.2.5 Optional Tools and Components.................... 3-13

3.3 INSTALLING THE ANALYZER .......................3-14

3.3.1 Analyzer AC Power Wiring ........................... 3-14

3.3.2 Sample and Gas Lines.................................. 3-15

3.4 SETTING THE COM ID ................................. 3-18

3.4.1 Inspect or Change the Com ID ...................... 3-18

3.4.2 Preparing for Serial Connections.................... 3-22

3.4.3 FTB Connection (RS-232)............................. 3-24

3.4.4 PC to GC Cable Short Distance Connection

(RS-232) .................................................... 3-25

3.4.5 Long Distance Connection (RS-422, RS-485).. 3-32

INSTALLATION AND SETUP MAY 2008

Model 1000A

TABLE OF CONTENTS iii

3.4.6 Ethernet Connection (Optional) ....................3-33

3.4.7 GC-Printer Wiring ........................................ 3-34

3.4.8 Discrete Digital I/O Wiring ............................3-35

3.4.9 Analog Input Wiring.....................................3-38

3.4.10 Analog Output Wiring .................................. 3-39

3.4.11 Optional Boards ..........................................3-41

3.5 ANALYZER LEAK CHECKS AND PURGING FOR

FIRST CALIBRATION ...................................3-43

3.5.1 Analyzer Leak Checks.................................. 3-43

3.5.2 Purging Carrier Gas Lines ............................. 3-44

3.5.3 Purging Calibration Gas Lines........................3-46

3.6 SYSTEM START-UP ....................................3-47

MAINTENANCE AND

TROUBLESHOOTING

4.1 HAZARDOUS ENVIRONMENTS.......................4-1

4.2 TROUBLESHOOTING AND REPAIR CONCEPT ...4-2

4.3 ROUTINE MAINTENANCE...............................4-2

4.3.1 Bimonthly Maintenance Checklist ....................4-2

4.3.2 Routine Maintenance Procedures.....................4-4

4.3.3 Contact Service ............................................4-4

4.4 ACCESS TO GC EQUIPMENT ELEMENTS .........4-4

4.4.1 Electrical/Electronic Components.....................4-4

4.4.2 Detector Elements, Heater Elements, Valves and

Columns ......................................................4-7

4.5 PRECAUTIONS FOR HANDLING PC

ASSEMBLIES ................................................4-9

4.6 GENERAL TROUBLESHOOTING.......................4-9

4.6.1 Hardware Alarms ..........................................4-9

4.6.2 Troubleshooting Checklist ............................ 4-12

4.6.3 Test Points Dual Methods Board and FTB .......4-15

MAY 2008 MAINTENANCE AND TROUBLESHOOTING

iv TABLE OF CONTENTS

Model 1000A

4.6.4 Preamplifier ................................................ 4-17

4.6.5 Flow Balance Check .................................... 4-17

4.6.6 Temperature............................................... 4-17

4.6.7 FID Configuration ........................................4-19

4.7 LEAK CHECKS............................................ 4-20

4.7.1 Field Service............................................... 4-20

4.7.2 Factory Level Leak Check............................. 4-21

4.7.3 Plugged Lines, Columns, or Valves ................ 4-23

4.8 CHROMATOGRAPH VALVES........................ 4-24

4.8.1 Required Tools............................................ 4-24

4.8.2 Chromatograph Valve Replacement Parts ....... 4-24

4.8.3 Valve Cleaning............................................4-25

4.8.4 Valve Overhaul ...........................................4-25

4.8.5 TCD Replacement ....................................... 4-27

4.8.6 Micro-FID Removal ...................................... 4-29

4.8.7 Micro-FID Maintenance ................................ 4-31

4.8.8 Micro-FID Re-assembly ................................4-32

4.9 TCD DETECTOR BRIDGE BALANCE............... 4-32

4.10 MEASURE VENT FLOW ...............................4-35

4.11 MODEL 1000A ELECTRICAL COMPONENTS ..4-36

4.11.1 DC Power Supply Replacement Procedures..... 4-39

4.12 COMMUNICATIONS ....................................4-40

4.13 ANALOG INPUTS/OUTPUTS......................... 4-43

4.13.1 Model 1000A Analog Inputs......................... 4-44

4.13.2 Analog Output Adjustment ...........................4-45

4.13.3 Model 1000A Analog Outputs ...................... 4-46

4.14 DISCRETE DIGITAL INPUTS/OUTPUTS ..........4-48

MAINTENANCE AND TROUBLESHOOTING MAY 2008

Model 1000A

TABLE OF CONTENTS v

4.15 RECOMMENDED SPARE PARTS.................... 4-49

4.16 UPGRADE PROCEDURES .............................4-49

4.16.1 Base Operating System ................................4-49

4.16.2 Applications ...............................................4-49

RECOMMENDED SPARE

PARTS

APPENDIX A,

COMMUNICATIONS

SPECIFICATIONS

5.1 ANALYZER SPARES ......................................5-2

5.1.1 Printed Circuit Card Assemblies (Analyzer) .......5-2

5.1.2 Electrical and Mechanical Assemblies (Analyzer)5-2

A.1 TCD SERIAL COMMUNICATIONS................... A-1

A.1.1 Model 1000A with TCD Communications Ports A-2

A.2 FID SERIAL COMMUNICATIONS .................... A-5

A.2.1 Connecting Serial Communications to the GC .. A-8

A.2.2 FTB Serial Communications ..........................A-10

A.3 WIRING LOCAL RS-232 COMMUNICATIONS..A-21

A.3.1 GC Serial Port and Cable Configurations.........A-21

A.3.2 GC DB 9-pin Serial Port to PC DB 9-pin Port ...A-24

A.3.3 GC DB 9-pin Serial Port to PC DB 25-pin Port .A-25

A.3.4 GC PHOENIX Plug Port to PC DB 9-pin Port ....A-26

A.3.5 GC PHOENIX Plug Port to PC DB 25-pin Port ..A-27

A.4 WIRING REMOTE RS-232

COMMUNICATIONS ....................................A-28

A.4.1 GC DB 9-pin Serial Port to Modem DB 25-pin

Port...........................................................A-28

A.4.2 GC PHOENIX Plug to Modem DB 25-pin Port ..A-29

A.5 EXAMPLE RS-422 PC-GC CONNECTION ........A-30

A.6 EXAMPLE RS-485 PC-GC CONNECTION ........A-32

MAY 2008 RECOMMENDED SPARE PARTS

vi TABLE OF CONTENTS

Model 1000A

APPENDIX B, MODEM

INSTALLATION

APPENDIX C,

MANIFOLD CARRIER

FOR GAS BOTTLES

APPENDIX D, LOCAL

OPERATOR INTERFACE

B.1 OPTIONAL INTERNAL MODEM .......................B-1

B.1.1 Optional Ethernet Board ................................. B-3

C.1 CARRIER GAS ..............................................C-1

C.2 INSTALLATION AND LINE PURGING................C-2

C.3 REPLACING CARRIER CYLINDER ....................C-3

C.4 CALIBRATION GAS .......................................C-3

D.1 INTERFACE COMPONENTS FOR DISPLAYING AND

ENTERING DATA ..........................................D-1

D.1.1 Light Emitting Diode Indicators........................D-1

D.1.2 LCD Screen ..................................................D-2

D.1.3 Keypad ........................................................D-2

D.1.4 Security Switch ............................................D-2

D.2 USING THE LOCAL OPERATOR INTERFACE .....D-3

APPENDIX E,

ENGINEERING

DRAWINGS

D.2.1 Navigating the Screen....................................D-4

D.2.2 Editing Numeric Data .....................................D-4

D.2.3 Editing Non-Numeric Data ..............................D-5

D.3 NAVIGATING THE LOI MENUS .......................D-7

D.3.1 The Ctrl Menu ..............................................D-9

D.3.2 The App Menu............................................D-14

D.3.3 The Chrom Menu ........................................D-23

D.3.4 The Logs Menu ...........................................D-29

D.3.5 The Manage Menu ......................................D-37

E.1 LIST OF ENGINEERING DRAWINGS ................. E-1

APPENDIX B, MODEM INSTALLATION MAY 2008

Model 1000A

DESCRIPTION

1.1 PURPOSE OF THIS MANUAL

The Emerson Process Management Model 1000A Gas Chromatograph
System Hardware Reference Manual (P/N 3-9000-750) is intended as a

user's guide to accompany the MODEL 1000A GAS CHROMATOGRAPH
SYSTEM.

NOTE: For software operation instructions, see the MON2000
Software for Gas Chromatographs User Manual (P/N 3-9000-522).

This manual provides the following information:

• A general description of the Model 1000A Gas Chromatograph (GC)
System and its components, their configurations and functions.
(Section 1: Description)

DESCRIPTION 1-1

• A brief description of the GC System's software, user interfaces, and
capabilities. (Section 1: Description)

• Introduction to GC theory of operation and terminology. (Section 1:
Description)

• Guidelines for sampling system and gas connections. (Section 2:
Equipment Description)

• Descriptions of Analyzer subsystems and components. (Section 2:
Equipment Description)

• Descriptions of GC Controller subsystems and components. (Section 2:
Equipment Description)

• Instructions for installing the GC System hardware. (Section 3:
Installation and Startup)

• Instructions for regular maintenance and care of the GC System
hardware. (Section 4: Maintenance)

• Instructions for troubleshooting, repair, and service of the GC System
hardware. (Section 4: Maintenance)

• List of boards, valves, and other components suggested as spare parts.
(Section 5: Recommended Spare Parts)

JUNE 2008 PURPOSE OF THIS MANUAL

1-2 DESCRIPTION

• Appendices with additional, helpful reference materials and drawings.
(Appendices)

1.2 INTRODUCTION

The Emerson Process Management Model 1000A Gas Chromatograph is
a high-speed GC system that is factory engineered to meet specific field
application requirements based on stream composition and the
anticipated concentration of the components of interest. The GC system
typically consists of two major components, the Analyzer Assembly and
the Sample Conditioning System:

• Analyzer Assembly (Model 1000A Series)

Located near the sample tap in a freeze-protected shelter. The
Analyzer includes columns, detectors, preamplifier, stream switching
valves, solenoids, and the GC, which includes electronics and ports for
signal processing, instrument control, data storage, personal
computer (PC) interface, and telecommunications.

Model 1000A

• Sample Conditioning System (SCS)

Located between the process stream and the Analyzer sample inlet,
usually mounted on the lower portion of the Analyzer stand. The
standard configuration SCS includes a mounting plate, block (or
shutoff) valves, and filters. Optionally, the SCS can be configured with

Genie® bypass filters, liquid shut-off valves, and optional solenoids for
stream switching; all of which can be enclosed in an electric (heat tape
design) oven.

In its standard configuration, the Model 1000A series Analyzer can
handle up to five streams: typically, four for sample and one for
calibration. With an optional stream switch assembly added, the GC can
switch up to twelve streams, maximum.

Although the GC is designed to be operated primarily from the LOI, you
can also use a personal computer (PC) running MON2000. The PC option
provides the user with the greatest capability, ease-of-use, and flexibility.
One PC running MON2000 can connect with up to 32 chromatographs
(via RS-485 serial communications links). The PC is used to display
analysis chromatograms and reports, which can then be stored to files on
the PC hard drive, or printed from either the PC's printer port or the GC's
printer port.

INTRODUCTION JUNE 2008

Model 1000A

Since neither the PC nor a normal printer can be placed in a hazardous
area, serial port and Modbus communications links are provided for
connecting the GC to the PC, other computers, printers, and controllers.

1.3 FUNCTIONAL DESCRIPTION

A functional block diagram of a typical GC installation is shown in Figure

1-1. A sample of the gas to be analyzed is taken from the process stream

by a sample probe installed in the process line. The sample passes
through a sample line to the sample conditioning system where it is
filtered or otherwise conditioned. After conditioning, the sample flows to
the Analyzer for separation and detection of the components of the gas.

The chromatographic separation of the sample gas into its components is
accomplished in the Analyzer in the following manner. A precise volume
of sample gas is injected into one of the unit's analytical columns. The
column contains a stationary phase (packing) that is either an active solid
(adsorption partitioning) or an inert solid support that is coated with a
liquid phase (absorption partitioning). The gas sample is moved through
the column by means of a mobile phase (carrier gas). Selective
retardation of the components of the sample takes place in the column
that causes each component to move through the column at a different
rate. This action separates the sample into its constituent components.

DESCRIPTION 1-3

A detector located at the outlet of the analytical column senses the
elution of components from the column and produces electrical outputs
proportional to the concentration of each component. Outputs from the
Analyzer detectors are amplified in the Analyzer electronics, then
transmitted to the GC for further processing. See Section 1.6 for more
information.

Although output from the GC is normally displayed on the LOI, it can
also be displayed on a remotely located personal computer or a printer.
Connection between the GC and the PC can be accomplished via a direct
serial line or via the Modbus-compatible communication interface.

Multiple chromatograms may be displayed on the LOI and compared or
contrasted with separate color schemes. This allows a stored
chromatogram to be compared/contrasted with a current or another
stored chromatogram. This could be of great assistance when changing
parameters or isolating a problem.

JUNE 2008 FUNCTIONAL DESCRIPTION

1-4 DESCRIPTION

Model 1000A

In most instances, it is essential to use a PC for detailed troubleshooting
procedures. Basic operations should be performed from the LOI that is
built into the Model 1000A. With optional electronic boards, the PC can
be connected remotely via ethernet, telephone, radio or satellite. Once
installed and configured, the GC can operate independently for long
periods of time.

Figure 1-1 GC System Functional Block Diagram

FUNCTIONAL DESCRIPTION JUNE 2008

Model 1000A

1.4 MINIMUM PC REQUIREMENTS

To achieve maximum performance when running the MON2000 software,
ensure your PC system contains the following hardware and software
equipment.

• PC with a 486/90 MHz or higher processor (Pentium/100MHz or

higher recommended) running:

- Windows® 95 (service pack 1 or better) or later

NOTE: If running Windows® 95 with the optional ethernet card, the
user must download Socket 2 from www.microsoft.com/windows95/
downloads to utilize MON2000’s ethernet feature.

- Windows® 98 version 1 or later

DESCRIPTION 1-5

- Windows® 2000 version 1 or later

- Windows® XP version 1 or later (see note for system requirements)

- Windows® Vista version 1 or later

NOTE: You must have administrator privileges to intall MON2000
because Vista will not allow a ‘standard’ user to install software.
Even with administrator privileges, you will be prompted by Vista’s
User Account Control feature to allow or cancel the installation. For
more details, refer to Getting Started with User Account Control on
Windows Vista (http://go.microsoft.com/fwlink/?LinkID=102562).

- Windows® NT version 4 (service pack 3 or later)

• 16 MB of RAM (32 MB or higher recommended)

• 5 MB of free hard disk space

• Super VGA monitor with 800x600 resolution

• Free serial port for remote/local connection to gas chromatograph (for

online operations)

• Free parallel port for connection to printer

• Windows®-compatible modem (for remote connection only)

JUNE 2008 MINIMUM PC REQUIREMENTS

1-6 DESCRIPTION

NOTE: Microsoft Internet Explorer 5.0 is required to view
spreadsheets or reports saved in HTML format.

•Use the Settings → Control Panel → System → General Page menu
path to check the system version number.

- For Windows® 95, the version number should be 4.00.950A/B or

later.

- For Windows® 98 or Windows® 2000, the version number should

be 1 or later.

- To use Windows® XP you need a PC with 300 MHz or higher

processor clock speed recommended; 233 MHz minimum required
(single or dual processor system);* Intel® Pentium®/Celeron®

family, or AMD K6®/Athlon™/Duron™ family, or compatible
processor recommended.

- Memory 128 MB of RAM or higher recommended (64 MB minimum

supported; may limit performance and some features)

Model 1000A

- Hard Disk Minimum: 1.5 GB of available hard disk space

- For Windows NT4, the version number should be 4.00.1381 or

later.

1.5 MODES OF OPERATION

1.5.1 User Interface

You have two user interfaces from which to operate the gas
chromatograph (GC) system: the LOI or a PC connected to the GC and
running MON2000.

The LOI allows you to gather basic information and to perform
maintenance repairs at the GC site.

A PC connected to the GC and running MON2000 offers the greatest
amount of capability and flexibility.

Find complete user instructions for MON2000 in the program’s online
HELP manual as well as in the MON2000 Software for Gas
Chromatographs User Manual (P/N 3-9000-522).

MODES OF OPERATION JUNE 2008

Model 1000A

1.5.2 Capabilities

Some of the individual GC controller functions that can be initiated or
controlled by the GC and its software, MON2000, include the following:

• Valve activations

• Timing adjustments

• Stream sequences

• Heater controls (when applicable)

• Calibrations

• Baseline runs

•Analyses

• Halt operation

DESCRIPTION 1-7

• Stream/detector assignments

• Stream/component table assignments

• Stream/calculation assignments

•Diagnostics

• Alarm and event processing

• Event sequence changes

• Component table adjustments

• Calculation adjustments

• Alarm parameters adjustments

• Analog scale adjustments

Some of the reports and logs that can be produced, depending upon the
GC application in use, include the following:

• Configuration report

• Parameter list

• Analysis chromatogram

• Chromatogram comparison

JUNE 2008 Capabilities

1-8 DESCRIPTION

• Alarm log (unacknowledged and active)

•Event log

• Analysis raw data

1.6 THEORY OF OPERATION

NOTE: See Section 1.7 for definitions of some of the terminology used
in the following explanations.

1.6.1 Analyzer Detector

The Analyzer detector subsystem is a thermal conductivity detector that
consists of a balanced bridge network with heat-sensitive thermistors in
each leg of the bridge. Each thermistor is enclosed in a separate chamber
of the detector block. One thermistor is designated the reference element
and the other the measurement element. A schematic diagram of the
thermal conductivity detector is shown in Figure 1-2.

Model 1000A

THEORY OF OPERATION JUNE 2008

Model 1000A

In the quiescent condition (prior to injecting a sample), both legs of the
bridge are exposed to pure carrier gas. In this condition, the bridge is
balanced and the bridge output is electrically nulled. The bridge can be
balanced by the fine and coarse adjustment potentiometers located on the
preamplifier circuit board.

The analysis begins when a fixed volume of sample is injected into the
column by operation of the sample valve. The sample is moved through
the column by the continuous flow of carrier gas. As successive
components elute from the column, the temperature of the measurement
element changes. The temperature change unbalances the bridge and
produces an electrical output proportional to the component
concentration. The differential signal developed between the two
thermistors is amplified by the preamplifier.

DESCRIPTION 1-9

Figure 1-2 Schematic Diagram of Analyzer Detector Bridge

Figure 1-3 illustrates the change in detector electrical output during

elution of a component.

3

1

detector bridge balanced

1

component begins to elute from column

2

and is measured by thermistor
peak concentration of component

3

Figure 1-3 Detector output during component elution

2

1

JUNE 2008 Analyzer Detector

1-10 DESCRIPTION

In addition to amplifying the differential signal developed between the
detector's two thermistors, the preamplifier also supplies drive current to
the detector bridge. The preamplifier also supplies drive current to the
detector bridge. The voltage signal is converted to a 4 to 20-milliamp
(mA) current loop for transmission to the GC Controller.

The signal is proportional to the concentration of a component detected in
the gas sample. The preamplifier provides four different gain channels as
well as compensation for baseline drift.

The signals from the preamplifier are sent to the GC Controller for
computation, recording on a printer, or viewing on a PC monitor or LOI.

1.6.2 Data Acquisition

Every second, exactly 40 equi-spaced data samples are taken for analysis
by the GC (i.e., once every 25 milliseconds). Each data sample, after
having been precision-amplified, is subjected to a twelve bit analog to
digital (A/D) conversion. The sampling frequency of 40 Hertz (Hz) was
chosen to reduce 60 Hz normal mode noise.

Model 1000A

After each point on the chromatograph signal is sampled, the resulting
number is stored in a buffer area in the GC’s memory for processing.
During the analysis, only the last 256 data points are available for
processing. Because the data analysis is done as the signal is sampled (in
real-time), only a limited number of past data samples is required to
analyze any signal.

As a part of the data acquisition process, groups of incoming data samples
are averaged together before the result is stored to the GC’s memory for
processing. Non-overlapping groups of N samples are averaged and
stored, and thus reduce the effective incoming data rate to 40/N samples/
second. For example, if N = 5, then a total of 40/5 or 6 (averaged) data
samples are stored every second. The value for the variable N is
determined by the selection of a Peak Width (PW) parameter. The
relationship is:

N PW ondssec=

Data Acquisition JUNE 2008

Model 1000A

where PW is given in seconds. All the various details in the analysis
process are independent of the value of N. Allowable values of N are 1 to
63, which corresponds to values of PW from 2 to 63 seconds.

The variable N is known as the integration factor. This term is used
because N determines how many points are averaged or integrated to
form a single value. The integration of data upon input, before storing,
serves two purposes. First, the statistical noise on the input signal is
reduced by the square root of N. In the case of N = 4, a noise reduction of
two would be realized. Secondly, the integration factor controls the
bandwidth of the chromatograph signal. It is necessary to match the
bandwidth of the input signal to that of the analysis algorithms in the
GC. This prevents small, short duration perturbations from being
recognized as true peaks by the program. It is therefore important to
choose a Peak Width corresponding to the narrowest peak in a group
under consideration.

DESCRIPTION 1-11

1.6.3 Peak Detection

For normal area or peak height concentration evaluation, the
determination of a peak's start, peak point, and end is automatic. The
manual determination of start and end points is used only for area
calculations in the Forced Integration mode. Automatic determination of
peak onset or start is initiated whenever Integrate Inhibit is turned off.
Analysis is started in a region of signal quiescence and stability, such
that the signal level and activity can be considered as baseline values. It
is important that this be the case because the assumption is made by the
GC software.

Having initiated a peak search by turning Inhibit off, the GC performs a
point by point examination of the signal slope. This is achieved by using
a digital slope detection filter which is a combination low pass filter and
differentiator. The output of this detector is constantly compared to a
system constant entered by the operator called Slope Sensitivity. A
default value of 8 is assumed if no entry is made. Lower values make
peak onset detection more sensitive, and higher values make detection
less sensitive. Higher values (20 to 100) would be appropriate for noisy
signals, e.g. high amplifier gain.

Peak termination is determined by the same application of this detector
to the signal, but in the reverse sense. Onset is defined where the

JUNE 2008 Peak Detection

1-12 DESCRIPTION

Model 1000A

detector output exceeds the baseline constant, but termination is defined
subsequently where the detector output is less than the same constant.

Sequences of fused peaks are also automatically handled. This is done by
testing each termination point to see if the region immediately following
it satisfies the criteria of a baseline. A baseline region must have a slope
detector value less than the magnitude of the baseline constant for a
number of sequential points. When a baseline region is found, this
terminates a sequence of peaks.

A zero reference line for peak height and area determination is
established by extending a line from the point of the onset of the peak
sequence to the point of the termination. The values of these two points
are found by averaging the four integrated points just prior to the onset
point and just after the termination points, respectively. The zero
reference line will, in general, be non-horizontal, and thus compensates
for any linear drift in the system from the time the peak sequence starts
until it ends.

In a single peak situation, peak area is the area of the component peak
between the curve and the zero reference line. The peak height is the
distance from the zero reference line to the maximum point on the
component curve. The value and location of the maximum point is
determined from quadratic interpolation through the three highest points
at the peak of the discrete valued curve stored in the GC.

For fused peak sequences, this interpolation technique is used both for
peaks as well as valleys (minimum points). In the latter case, lines are
dropped from the interpolated valley points to the zero reference line to
partition the fused peak areas into individual peaks. The use of
quadratic interpolation improves both area and height calculation
accuracy and eliminates the effects of variations in the integration factor
on these calculations.

For calibration, the GC may average several analyses of the calibration
stream.

Peak Detection JUNE 2008

Model 1000A

1.6.4 Basic Analysis Computations

Two basic analysis algorithms are included in the GC. These are:

• Area Analysis - Calculates area under component peak

• Peak Height Analysis - Measures height of component peak

Concentration Analysis by Using Response Factor

Concentration calculations require a unique response factor foreach
component in an analysis. These response factors may be manually
entered by an operator or determined automatically by the system
through calibration procedures (with a calibration gas mixture that has
known concentrations).

Response factor calculation: (using the external standard)

DESCRIPTION 1-13

or

where:

ARF

n

HRF

n

Area

n

Ht

n

Cal

n

Area

n

-------------- -

=

ARF

n

Cal

n

Ht

n

-----------

=

HRF

n

Cal

n

Area response factor for component n in area per mole percent (%).

Height response factor for component n.

Area associated with component n in calibration gas.

Height associated with component n in mole percent in calibration gas.

Amount of component n in mole percent in calibration gas.

Calculated response factors are stored by the GC for use in the
concentration calculations, and are printed out in the configuration and
calibration reports.

JUNE 2008 Basic Analysis Computations

1-14 DESCRIPTION

Average response factor is calculated as follows:

k

∑

i 1=

RFAVG

where:

RFAVGnArea or height average response factor for component n.

=

n

------------------

k

RF

Model 1000A

i

Rf

i

Area or height response factor for component n from the calibra­tion run.

k Number of calibration runs actually used to calculate the response

factors.

The percent deviation of new RF averages from old RF average is
calculated in the following manner:

% deviation

new

------------------------------------- -

RF

old

old

100×=

RF

∠

RF

where the absolute value of % deviation for alarm has been previously
entered by the operator.

Concentration Calculations in Mole % without Normalization

Once response factors have been determined by the GC or entered by the
operator, component concentrations are determined for each analysis by
using the following equations:

Area

n

-------------- -

CONC

=

n

ARF

n

Basic Analysis Computations JUNE 2008

Model 1000A

or

where:

CONCnConcentration of component n in mole percent.

CONC

DESCRIPTION 1-15

Ht

n

--------------

=

n

HRF

n

Area

ARF

Area of component n in unknown sample

n

Response factor of component n calculated from area of calibration

n

sample. Units are area per mole percent.

Ht

n

HRF

Peak height of component n in unknown sample

Response factor of component n calculated from peak height of cal-

n

ibration sample. Units are height per mole percent.

Note that the average concentration of each component will also be
calculated when data averaging is requested.

Component concentrations may be input through analog inputs 1 - 4 or
may be fixed. If a fixed value is used, the calibration for that component
is the mole % that will be used for all analyses.

Concentration Calculations with Normalization

CONC

CONCN

n

----------------------------

∑

i 1=

k

CONC

n

100×=

i

where:

CONCN

CONC

CONC

k Number of components to be included in the normalization.

JUNE 2008 Basic Analysis Computations

Normalized concentration of component n in percent of total gas

n

concentration.

Non-normalized concentration of component n in mole percent.

n

Non-normalized concentration (in mole percent) from each of the k

i

components to be grouped into this normalization.

1-16 DESCRIPTION

NOTE: For additional information about other calculations that are
performed by the GC and software, see the MON2000 Software for
Gas Chromatographs User Manual (P/N 3-9000-522).

1.7 GLOSSARY

Auto Zero: Automatic zeroing of the preamplifier. May be entered into
the Controller to take place at any time during the analysis when either
the component is not eluting or the baseline is steady.

Chromatogram: A permanent record of the detector output. A
chromatograph is obtained from the LOI or from a PC interfaced with the
detector output through the GC. A typical chromatogram displays all
component peaks, and gain changes. It may be viewed in color as it is
processed on the LOI or a PC VGA display. Tick marks recorded on the
chromatogram by the GC indicate where timed events take place.

Model 1000A

Component: Any one of several different gases that may appear in a
sample mixture. For example, natural gas usually contains the following
components: nitrogen, carbon dioxide, methane, ethane, propane,
isobutane, normal butane, isopentane, normal pentane, and hexanes
plus.

Condulet: Fitting resembling a pipe or a box with a removable cover for
access to electric conduits.

CTS: Clear to send (a serial port pin assignment).

DCD: Data carrier detect; see also, RLSD (a serial port pin assignment).

DSR: Data set ready (a serial port pin assignment).

DTR: Data terminal ready (a serial port pin assignment).

LOI: Local operator interface; an integrated color display panel with

infrared touchkeys that allows you to interact with the GC.

Response Factor: Correction factor for each component as determined
by the calibration. See “Concentration Analysis by Using Response

Factor” on page 13 for more information.

GLOSSARY JUNE 2008

Model 1000A

Retention Time: The time (in seconds) that elapses between start of
analysis (0 seconds) and the sensing of the maximum concentration of
each component by the Analyzer detector.

RI: Ring indicator (a serial port pin assignment).

RLSD: Received line signal detect (a digital simulation of carrier detect);

see also, DCD (a serial port pin assignment).

RTS: Request to send (a serial port pin assignment).

RxD, RD, or SIN: Receive data, or signal in (a serial port pin

assignment).

DESCRIPTION 1-17

TxD, TD, or S

assignment).

: Transmit data, or signal out (a serial port pin

OUT

JUNE 2008 GLOSSARY

1-18 DESCRIPTION

This page is intentionally left blank.

Model 1000A

GLOSSARY JUNE 2008

Model 1000A

EQUIPMENT DESCRIPTION

This section provides descriptions of the various subsystems and
components that make up the Model 1000A Gas Chromatograph (GC)
system.

2.1 SAMPLING SYSTEM

A well designed, properly adjusted sampling system is essential to
optimum performance of any gas chromatograph. If a good sample is not
obtained for analysis, the whole purpose of the system is compromised.

The purpose of the sample handling system is to transfer a conditioned
fluid sample that is compatible with gas chromatography requirements.

The Sample Conditioning System (SCS) is located between the process
stream and the Analyzer, and is usually mounted on the lower portion of
the Analyzer stand. It serves these purposes:

EQUIPMENT DESCRIPTION 2-1

• Extracts final sample from the fast loop,

• Performs final filtration,

• Performs stream switching for a multi-stream Analyzer, and

• Adjusts the final pressure, temperature, and flow control on the

selected sample flowing to the sample valve.

The following points should be considered in selecting and installing a
sampling system:

• Sample Point

• Sample Volume and Flow Rate

• Sample Conditioning

• Contamination Precautions

•Valving

• Calibration Gas

JUNE 2008 SAMPLING SYSTEM

2-2 EQUIPMENT DESCRIPTION

2.1.1 Sampling Point Location

Gas samples must be representative of the process stream and must be
taken from a location where stratification or separation of components
does not occur. The sampling point should be as close as feasible to the
Analyzer.

2.1.2 Sample Volume and Flow Rate

An adequate response time for sample analysis requires that sample
volumes should generally be as small as possible, and the flow rate
between the sampling point and the Analyzer should be as high as
possible, consistent with accuracy. To minimize time lag and to prevent
back diffusion, dryers and filters in the sampling line should be as small
as possible. When long sampling lines cannot be avoided, flow velocity in
the line can be increased by decreasing the downstream pressure.

Typically, pressure is reduced at the sample point with a pressure
regulating sample probe. The input pressure to the Analyzer can be
adjusted between 15 and 30 pounds per square inch, gauge (psig).
Reducing the pressure at the sample point avoids the problem of heavy
liquid dropout in the sample line during cold weather. The flow rate in
the sample line is set at 50 cubic centimeters (cc) per minute with the
restrictor valve at the Analyzer.

Model 1000A

The Model 1000A is capable of accepting liquid phase samples also. In
this case, the pressure is regulated by means of a back pressure regulator
located on the SCS mounting plate. If the stream is at ambient pressure
or under slight vacuum, an educator or pump may be used to force sample
through the sample loop. In this situation, sample shut-off technique
with equalizing coil is employed to ensure consistency of the sample
volume.

Use this general rule to approximate sample lag time caused by the
length of sample line:

length of sample tubing

lag time

Sampling Point Location JUNE 2008

--------------------------------------------------------

=

flow rate of sample

Model 1000A

Sample line constructed of 1/8-inch tubing contains approximately one
cubic centimeter of volume per foot. Therefore, with a flow rate of 50
cubic centimeters per minute, the lag time of the sample between the
sample point and the Analyzer is calculated by dividing the length of the
line (in feet) by 50. For example, the sample in a 100 foot sample line will
take two minutes to travel the length of the line.

2.1.3 Sample Conditioning

Sample systems should contain at least one filter to remove solid
particles from the sample stream. Most applications require fine-element
filters upstream of the Analyzer.

2.1.4 Contamination Precautions

Several precautions are recommended to minimize the possibility of
contaminating samples. Except in special applications, filters should be
of either the ceramic or the porous metallic type to avoid the absorption
losses characteristic of fiber or paper filters. Pressure regulators and flow
controllers containing cork or felt filters or absorbent diaphragms should
not be used. Sampling lines for noncorrosive streams should be stainless
steel tubing and must be clean and free of grease. Lines must be pressure
tight to prevent diffusion of moisture or atmospheric gases into the
sample. Pipe threads should be dressed only with Teflon tape on pipe
threads and never with pipe thread compounds (dope).

EQUIPMENT DESCRIPTION 2-3

2.1.5 Valving

A block valve should be installed immediately downstream of the sample
takeoff point to permit shutdown of the system for maintenance. Block
valves should be either gate valves or cocks of the proper material and
packing, and should be rated for the process line pressure. Tight seating
of all connections is essential.

2.1.6 Calibration Gas

A calibration gas used for Process analysis should be blended to Primary
Standards. Primary Standards are blended using weights that are
traceable to the National Bureau of Standards (NBS). If the calibration
standard is a gas, the standard should not have any component that could
drop out at the coldest temperature to which the gas will be subjected.

JUNE 2008 Sample Conditioning

2-4 EQUIPMENT DESCRIPTION

If a liquid calibration standard is being used, the head pressure must be
sufficient to prevent bubble-out of components during hot weather.

2.2 ANALYZER

2.2.1 Physical Description

The Analyzer is physically divided into two major sections. The upper
section contains the following components:

• Pneumatically actuated valves that control the flow of the sample and
carrier gases

• Valve control

• Heater-block temperature control

• Detector control

Model 1000A

• Detector output signal preamplifier

• GC Controller

The lower section is temperature controlled and contains:

• Detector elements

-TCDs

-FIDs

- Both

• Analytical columns

• Chromatograph valves

• A temperature-controlled heater block

The GC is mounted in a self-supporting rack that should be placed at or
near the sample tap. At a minimum, a three-sided shelter is
recommended.

ANALYZER JUNE 2008

Model 1000A

2.2.2 Chromatograph Valves

A chromatograph valve is shown in Figure 2-1 in exploded view. Its
pistons are pneumatically actuated in both switching directions by the
actuating assemblies located below the primary plate.

EQUIPMENT DESCRIPTION 2-5

Figure 2-1 Chromatograph Valve

JUNE 2008 Chromatograph Valves

2-6 EQUIPMENT DESCRIPTION

Model 1000A

Primary Plate

The primary plate contains precisely machined internal passages that
enter and exit the valve at top ports, each of which is connected to the top
and/or bottom of the plate within the valve. The primary plate, which is
the only metallic element that comes in contact with the sample, is
isolated from the remainder of the valve by specially formulated
diaphragms.

NOTE: GC valves should be torqued to 30 ft. lbs.

Actuating Subassemblies

Below the primary plate, pistons are operated by pneumatic pressure
applied to actuating diaphragms through ports in the base plate.

Operation

When pneumatic pressure is applied to the actuating diaphragms, the
pistons are actuated, thus forcing the sealing diaphragm against the
primary plate. This closes the passages that are connected at the bottom
of the plate. When pressure is removed, the pistons are free to move, and
flow is resumed through the passages.

2.2.3 Detector Subsystem

The operation of the Analyzer detector subsystem was previously
discussed in "THEORY OF OPERATION," Section 1.6.

2.2.4 Analyzer Preamplifier Unit

The electrical output from the detector is amplified by the Analyzer
preamplifier unit. The preamplifier also supplies drive current to the
detector bridge. The voltage signal is converted to a 4 to 20-milliamp
(mA) current loop for transmission to the GC. The signal is proportional
to the concentration of a component detected in the gas sample. The
preamplifier provides four different gain channels and compensates for
baseline drift. The signals from the preamplifier are then sent to the GC,
where they provide the basis for analysis computations and a chromato­graphic trace, or chromatogram.

Detector Subsystem JUNE 2008

Model 1000A

2.2.5 Analyzer Specifications

Power Requirements: 120 volts, alternating current (VAC), +10/

-15VAC; 50 to 60 Hertz (Hz); single phase; 10 amperes (A) (maximum
during warmup) (additional 10 amps if unit has a Sample System Oven).

Operating Temperature Range: -18 degrees Celsius (°C) to +55°C (0°F
to +130°F)

Humidity: 0 to 95 percent relative humidity, noncondensing

Frame Size (approximately):

• Height:78 inches (198 centimeters [cm])

• Width:24 inches (61 cm) maximum

• Depth:24 inches (61 cm)

EQUIPMENT DESCRIPTION 2-7

Weight: Approximately 125 pounds (56.8 kilograms [kg]), including
mounting hardware.

Sample Requirements:

• Fluid Phase - Vapor

• Pressure - 15 to 30 psig, regulated to ±10 percent

• Flow Rate - 50 cc/min, typical

Analyzer Output Signal: Four different gain channels to provide a 4 to
20 mA signal to the Controller.

Transient Over Voltages Category: Installation Category (Over
Voltage Category II)

Cleaning requirements: For external cleaning, use detergent and
water, as well as a non-abrasive drying material. For internal
maintenance of the analytical valves, refer to "Valve Cleaning," Section

4.8.3.

JUNE 2008 Analyzer Specifications

2-8 EQUIPMENT DESCRIPTION

2.2.6 Utility Gas Requirements

Carrier Gas: Application dependent; typically zero grade helium,
hydrogen or nitrogen (99.995% pure, with less than 5 ppm water, and less
than 0.5 ppm hydrocarbons); pressure is variable.

Valve Actuation Gas: Zero grade, 99.995% pure helium at 100 psig.
Consumption is 100cc per analysis cycle. Clean, dry air also may be used
for valve actuation.

Carrier gas and valve actuation gas are normally supplied from a
common cylinder, since overall gas consumption is minimal.

2.3 ELECTRONIC ASSEMBLY

The electronic assembly provides the GC with highly accurate timing,
precise calculations, report generation, and an interface with other
devices. The assembly provides analog outputs and a direct digital link
with output devices through RS-232C, RS-422, and RS-485 ports. Vital
portions of the controller are protected by a lithium battery backup in
case normal power is lost or turned off at the unit.

Model 1000A

The GC controller can be linked directly to a PC by a serial connection, by
a telecommunication link that uses Modbus protocol, or by an ethernet
connection, which is the preferred method for operating the GC.

WARNING: SERIOUS INJURY OR DEATH POSSIBLE

Do not operate a PC or printer in a hazardous environment. Failure
to observe all safety precautions could result in serious injury or
death.

2.3.1 Controller Hardware Configurations

The unit consists of an STD-bus based computer and related boards,
including boards for terminating field wiring. Connections to the
enclosure are through one 2-inch (50mm) hole (reduced to 3/4 inch with
bushing) and two 1-inch (25 mm) conduit fittings located in the bottom.
These accept matching conduit or cable entries. Field connections are
made through purged conduit or flameproof glands.

Utility Gas Requirements JUNE 2008

Model 1000A

For operating a printer (in a nonhazardous area) at the GC site, a DB-25
parallel port is available on the GC's Terminal Board (TB) for field
wiring.

The electronic assembly contains a DB-9 serial port connector for
connecting a PC to the GC at the GC site (for setup, operation, or
maintenance in a nonhazardous area).

The STD-Bus Card Cage inside the electronics enclosure is equipped with
two cards. Card slots are preassigned so that cables can be consistently
routed.

Three optional boards are also available, any two of which can be piggy­backed on the CPU board. The optional boards are: the COM4A board,
the modem board, and the ethernet board. If the Radicom modem is used,
it must be the top board in the card cage assembly.

EQUIPMENT DESCRIPTION 2-9

An optional stream switching assembly (with either AC or DC solenoids)
can be controlled by the GC, allowing for switching up to 12 streams.

Analog Inputs and Outputs

The GC can accommodate eight fully differential analog 4 to 20 mA input
signals. Four of the analog inputs are used by the associated Analyzer,
and they are filtered with transient protection. The additional four input
ports provide the ability to accept signals from other Analyzers, so that
the analytical report of the chromatograph can include other information
on the gas stream, such as water or sulphur content. Transient
protection and shield terminations are available for these inputs.

There is capability for a maximum of twelve analog outputs. Four analog
outputs are available as standard components of the GC; the other eight
analog outputs are optional. All twelve analog outputs are current type:
4-20 mA, not isolated. If required, the standard four analog outputs can
be isolated and an optional board can be purchased with an additional
four isolated outputs, for a total of eight isolated analog outputs. Also, all
twelve analog outputs can be calibrated with MON2000.

JUNE 2008 Controller Hardware Configurations

2-10 EQUIPMENT DESCRIPTION

Digital Inputs and Outputs

The GC has up to 16 digital inputs that can be used as follows:

5 to read a Modbus address, as defined by DIP switch positions.

2 to indicate presence and type of front panel as defined by switch positions

1 Spare

1 temperature sensor input to shut off LCD backlight

1 GC alarm, optically isolated, with transient protection

5 stream flow alarms, optically isolated, with transient protection

1 photocell detector, front panel backlight (night on, day off)

The Controller has the capability of 19 digital outputs used as follows:

Model 1000A

6 Analyzer control

8 driver outputs for DC air solenoids (stream switching, 12 total streams)

5 alarms, optically isolated, with transient protection

The digital transient-protected discrete outputs can furnish up to 50 mA.
If more current is required (up to 0.5A), a special transient protection
plug-in module should be installed. See Appendix C for transient
protection module details.

Communications

There are three to six communication ports available (depending on
options package selected). The communications ports can use either RS­232, RS-422, or RS-485 protocol, selected by Data Interface Chips via the
CPU Board. The communications ports on these boards are normally
configured at the factory, as specified by the customer's communications
requirements. The Modbus switch positions are also normally set at the
factory as specified by the customer. If any changes need to be made in
the field, refer to the drawings in the rear of this manual.

Driver Outputs

The GC Controller has eight stream switch outputs, 120 mA continuous
current, which can be used to control optional AC or DC solenoid switch

Controller Hardware Configurations JUNE 2008

Model 1000A

boards. This increases stream switch capability from the standard
capability of four gas streams and 1 calibration gas (CAL) system to a
maximum capability of twelve streams.

Electrical/Mechanical Safety and Integrity - Certifications and
Classifications

The standard Model 1000A is approved for use in a non-hazardous or
general purpose location. If an optional Z-purge kit is purchased and
added to the Model 1000A, the unit is CSA-certified for a Class I, Division
2, Groups B, C and D area. The Temperature Code for both the standard
Model 1000A, and the Model 1000A with an optional Z-purge kit, is T3.

EQUIPMENT DESCRIPTION 2-11

NOTE: The optional stream switching assembly (AC or DC solenoid
systems) has provisions for eight stream routes, but adding this
option has the net effect of adding only seven more stream routes to
the standard stream capacity of five (thus giving a total stream
capacity of twelve). The reason is, when the optional stream switch
assembly is installed, one of the Analyzer’s standard five stream
routes becomes dedicated to the optional stream switch assembly.

GC Controller Circuit Board List

The GC circuit boards are inserted or attached to an STD-bus card cage
assembly. It has two boards inserted into the card cage, and two of the
boards are attached to the card cage outside.

There are three optional piggy-back boards which can attach to the CPU
Board via the PC 104 bus:

• Modem

• COM4A (serial ports 5, 6, 7, and 8)

• Ethernet board

The inserted circuit boards of the GC controller perform these functions:

JUNE 2008 Controller Hardware Configurations

2-12 EQUIPMENT DESCRIPTION

Table 2-1 Functions of Inserted Circuit Boards, GC Controller Card Cage Assembly

Model 1000A

Subsystems

CPU microproces­sor board

COM4A Board
(CPU daughter
board)

Modem (CPU
Daughter board)

Analog I/O board

[requires
MON2000, version

2.3 or later]

Handle Label
or Part Number Function(s)

MCM/LPM-6117 Microprocessor; control of

parallel printer port; control of
COM1, COM2, COM3, and
COM4 communication ports;
system memory; RS-422 serial
protocol; three timers, digital I/
O, and Disk on Chip. Additional
memory for higher capacity data
archives.

Control of COM5-8 BE-20767

telephone modem

Analog* Control of eight analog inputs (4

for user applications and 4 for
Analyzer-Controller intercon­nect) and two, six, or ten analog
outputs

See drawing
number...

DE-20782

BE-18044

Ethernet Card
(CPU daughter
board)

There are two circuit boards attached to the outside of the card cage:

•The System Interface and Driver Board

• The GC's Terminal Board for Field Wiring

The GC's Terminal Board for Field Wiring provides termination
connections for the following items:

• Communication ports (COM1, COM2, COM3, COM4, COM5, COM6,
COM7, and COM8)

• Analog inputs and outputs

PCM-NE 2000 Flexible, high-performance net-

working capability; broad
spectrum of software support
(from Windows® 95 to Netware
2000 architecture)

Controller Hardware Configurations JUNE 2008

Model 1000A

• Digital inputs and outputs

• Controller-Analyzer interconnections

• Parallel printer port

• Optional stream switching assemblies

The GC Controller's Terminal Board for Field Wiring also has sockets for
transient protection modules, and a 250 VAC, 2A fuse (5 x 20 mm) that
protects all of the boards from transient surges.

EQUIPMENT DESCRIPTION 2-13

NOTE: See drawing DE-20782 for an illustration of the GC
Controller's Terminal Board for Field Wiring.

NOTE: See Appendix C and drawing CE-18115 for a list of transient
suppression modules that are installed for various configurations of
the GC and its communication, analog output, and stream-switching
options.

The System Interface and Driver Board provides the following functions:

• Drivers for switching the eight optional valve solenoids

• Location for 8-position DIP switch to set the Modbus address

• Opto-isolation circuits for the discrete inputs and outputs

• Switching power supply and temperature shutdown circuit for the

LCD display

• RS-232 to RS-422 conversion for the LCD display

• Voltage-to-current conversion for the analog outputs

• Jumper for selecting driving voltage source for the 4-20 mA circuit

NOTE: See drawing CE-18118 for an illustration of the System
Interface and Driver board.

JUNE 2008 Controller Hardware Configurations

2-14 EQUIPMENT DESCRIPTION

This page is intentionally left blank.

Model 1000A

Controller Hardware Configurations JUNE 2008

Model 1000A

INSTALLATION AND SETUP

This section provides instructions for installing and setting up the Model
1000A Gas Chromatograph system.

NOTE: Because the Model 1000A Gas Chromatograph system is
available in different configurations, not all of the instructions in this
section may apply. In most cases, however, to install and set up a
Model 1000A Gas Chromatograph system, it is recommended that
you follow the instructions in nearly the same order as presented in
this manual. (Also see Table 3-1 for a summary of installation and
setup steps.)

INSTALLATION AND SETUP 3-1

JUNE 2008

3-2 INSTALLATION AND SETUP

Table 3-1 Summary of Installation and Setup Steps

Observe Precautions and Warnings

1
2
3
4
5
6

See Section 3.1

Plan Site Location
See Section 3.2

Obtain Supplies and Tools
See Section 3.2

Install Analyzer Wiring
See Section 3.3

Install Analyzer Sample & Gas Lines
See Section 3.3

Install GC Controller Wiring
See Section 3.4

Model 1000A

7
8
9

10

Perform Leak Checks
See Section 3.5

Purge Carrier Gas Lines
See Section 3.5

Purge Calibration Lines
See Section 3.5

Start Up GC System
See Section 3.6

JUNE 2008

Model 1000A

3.1 PRECAUTIONS AND WARNINGS

NOTE: The analyzer electronics and oven assembly, when housed
inside a purged enclosure, meet the certifications and classifications
identified in “Electrical/Mechanical Safety and Integrity -

Certifications and Classifications” on page 2-11. Emerson Process

Management does not, however, accept any responsibility for
installations of these, or any attached equipment, in which the
installation or operation thereof has been performed in a manner that
is negligent and/or non-compliant with applicable safety
requirements.

WARNING: EQUIPMENT DAMAGE OR PERSONAL INJURY

The responsible body shall operate the equipment as designed and
specified by the manufacturer. Failure to do so may cause personal
injury or damage to the equipment.

INSTALLATION AND SETUP 3-3

3.1.1 Hazardous Environments

Observe Precautions and

1

Warnings

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Follow these precautions if installing or operating the Model
1000A Analyzer instrumentation in a hazardous area:

1. Install and operate only the purged version of the Model 1000A in a

hazardous area.

2. Do not operate any printer or personal computer (PC) that is

connected to the GC in a hazardous area. To interface with a GC in a
hazardous area, use the Local Operator Interface (LOI) that is built
into the purged housing or, alternatively, use a PC that is remotely
connected to the GC and is located in a nonhazardous area.

JUNE 2008 PRECAUTIONS AND WARNINGS

3-4 INSTALLATION AND SETUP

Model 1000A

3. Ensure that field connections to the Analyzer and the GC are made
through purged conduit or flameproof glands.

WARNING: EQUIPMENT DAMAGE OR PERSONAL INJURY

Observe ALL applicable regulations when installing purged GC
units. Failure to observe all regulations when installing purged GC
units may result in noncompliance, equipment damage or personal
injury.

The purged analyzer housing is certified for use in locations where fire
and explosion hazards may exist, specifically, areas that are classified by
the National Electronics Code (NEC) as Class I, Division 2, Groups B, C,
and D. However, other regulations do apply. For example, all intercon­necting runs of cable through conduit must be sealed at least 18 inches
beyond the conduit's point of entry into certified purged housing. Consult
your company's policies and procedures and other applicable
requirements documents to determine appropriate wiring and
installation practices.

3.1.2 Power Source Wiring

1
2
3
4

Follow these precautions when installing AC power source
wiring to the Model 1000A Analyzer instrumentation:

1. All wiring must conform to the National Electric Code, local state or
other jurisdiction, and company standards and practices.

2. Provide single-phase, three-wire, AC power at 115 or 230 volts AC, 50­60 Hz.

3. Include a switch or circuit breaker that is marked as the power
disconnect device in the building installation in a safe area.

Observe Precautions and Warnings

Plan Site Location

Obtain Supplies and Tools

Install Analyzer Wiring

Power Source Wiring JUNE 2008

Model 1000A

4. Provide 20 ampere circuit breaker protection so that the major

components of the GC are protected by one circuit breaker.

5. Use multi-stranded copper conductor wire according to the following

recommendations:

(a) For power feed distances up to 250 feet (76 meters), use wire size

American Wire Gauge (AWG) 14 (18 Metric Wire Gauge, stranded).

(b) For power feed distances 250 feet to 500 feet (76 meters to 152

meters), use wire size AWG 12 (25 Metric Wire Gauge, stranded).

(c) For power feed distances 500 feet to 1000 feet (152 meters to 305

meters), use wire size AWG 10 (30 Metric Wire Gauge, stranded).

3.1.3 Signal Wiring

Observe Precautions and Warnings

1

Plan Site Location

2

INSTALLATION AND SETUP 3-5

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Follow these general precautions for field wiring digital and
analog input/output (I/O) lines:

1. Metal conduit must be used for all process signal wiring.

2. Metal conduit used for process signal wiring must be grounded at

conduit support points (grounding the conduit at multiple points helps
prevent induction of magnetic loops between the conduit and cable
shielding).

3. Use suitable lubrication for wire pulls in conduit to prevent wire

stress.

4. All process signal wiring should be a single, continuous length

between field devices and the GC. If, however, length or conduit runs
require that multiple wiring pulls be made, the individual conductors
must be interconnected with suitable terminal blocks.

5. Use separate conduits for AC voltage and DC voltage circuits.

JUNE 2008 Signal Wiring

3-6 INSTALLATION AND SETUP

6. Do not place digital or analog I/O lines in same conduit as AC power
circuits.

7. Use only shielded cable for digital I/O line connections.

(a) Ground the shield at only one end.
(b) Shield-drain wires must not be more than two AWG sizes smaller

than the conductors for the cable.

8. When inductive loads (relay coils) are driven by digital output lines,
the inductive transients must be diode clamped directly at the coil.

9. Any auxiliary equipment wired to the GC must have its signal
common isolated from earth/chassis ground.

NOTE: Any loop of extra cable left for service purposes inside the GC
purged housing must not be placed near the conduit entry for AC
power. This applies to all digital and analog I/O lines connecting to
the GC.

Model 1000A

If the above precaution is not followed, the data and control signals to
and from the GC can be adversely affected.

3.1.4 Electrical and Signal Ground

Observe Precautions and Warnings

1

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Follow these general precautions for grounding electrical and
signal lines:

1. For shielded signal conducting cables, shield-drain wires must not be
more than two AWG sizes smaller than the conductors for the cable.
Shielding is grounded at only one end.

2. Metal conduit used for process signal wiring must be grounded at
conduit support points (intermittent grounding of conduit helps

Electrical and Signal Ground JUNE 2008

Model 1000A

3. A clamp type ground lug (color green) is located on the inside bottom

4. A clamp type ground lug is located on the outside of the GC's case at

5. A single-point ground (the outside case ground lug) must be connected

INSTALLATION AND SETUP 3-7

prevent induction of magnetic loops between the conduit and cable
shielding).

front of the GC's electronics enclosure. Chassis ground conductors
(color code green) inside the electronics enclosure should be stranded,
insulated copper wire. These device chassis ground conductors should
all be connected to the clamp type ground lug.

the rear of the lower right (facing the operator panel) casting rib. This
ground point should be connected to a copper ground rod as described
in the next step.

to a copper-clad, 10-foot long, 0.75" diameter steel rod, which is
buried, full-length, vertically into the soil as close to the equipment as
is practical. (Grounding rod furnished by others.)

6. Resistance between the copper-clad steel ground rod and the earth

ground must not exceed 25 Ohms.

7. The equipment-grounding conductors used between the GC and the

copper-clad steel ground rod must be sized according to the following
specifications:

• Length, 15 feet or less- AWG 8, stranded, insulated copper wire
(4.6 meters)

• Length, 15 to 30 feet-AWG 6, stranded, insulated copper wire (4.6
to 9.1 meters)

• Length, 30 to 100 feet-AWG 4, stranded, insulated copper wire (9.1
to 30.5 meters)

8. All inter-enclosure equipment-grounding conductors must be
protected by metal conduit.

9. External equipment, such as data printers, that are connected to the
GC should be powered via isolation transformers to minimize the
ground loops caused by the internally shared safety and chassis
grounds.

JUNE 2008 Electrical and Signal Ground

3-8 INSTALLATION AND SETUP

3.1.5 Electrical Conduit

1

2

3

4

Follow these general precautions for conduit installation:

1. Conduit cutoffs must be square. Cutoffs must be made by a cold
cutting tool, hacksaw, or by some other approved means that does not
deform the conduit ends or leave sharp edges.

2. All conduit fitting threads, including factory-cut threads, must be
coated with a metal-bearing conducting grease, such as Crouse-Hinds
STL or equivalent, prior to assembly.

Model 1000A

Observe Precautions and Warnings

Plan Site Location

Obtain Supplies and Tools

Install Analyzer Wiring

3. Temporarily cap the ends of all conduit run runs immediately after
installation to prevent accumulation of water, dirt, or other
contaminants. If necessary, swab out conduits prior to installing the
conductors.

4. Install drain fittings at the lowest point in the conduit run; install
seals at the point of entry to the GC's purged housing to prevent vapor
passage and accumulation of moisture.

®

5. Use liquid-tight conduit fittings, such as Myers

Scru-Tite® or similar,

for conduit which is exposed to moisture.

When conduit is installed in hazardous areas (e.g., areas classified as
NEC Class I, Division 1, Groups B, C and D), follow these general
precautions for conduit installation:

1. All conduit runs must have an explosion-proof sealing (potting) fitting
located within 18 inches (45.5 centimeters) distance from the conduit
entrance to explosion-proof housings.

2. The conduit installation must be vapor tight, with threaded hub
fittings, sealed conduit joints and gaskets on covers, or other approved
vapor-tight conduit fittings.

Electrical Conduit JUNE 2008

Model 1000A

CAUTION: EQUIPMENT DAMAGE OR PERSONAL INJURY
Consult your company's policies and procedures and other applicable
requirements documents to determine wiring and installation
practices that are appropriate for hazardous areas. Failure to do so
may cause personal injury or damage to equipment.

3.1.6 Sample Systems Requirements

Observe Precautions and Warnings

1

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Observe the following guidelines for installing GC sample
systems:

INSTALLATION AND SETUP 3-9

Sample Line Length: If possible, avoid long sample lines. In case of a
long sample line, flow velocity can be increased by decreasing
downstream pressure and using by-pass flow via a speed loop.

Sample Line Tubing Material:

• Use stainless steel tubing for noncorrosive streams.

• Use treated stainless steel, such as Sulfinert or Silcosteel, for streams

that contain corrosives, such as hydrogen sulfide.

• Ensure tubing is clean and free of grease.

Dryers and Filters in Sample Line:

• Use small sizes to minimize lag time and prevent back diffusion.

• Install a minimum of one filter to remove solid particles. Most

applications require fine-element filters upstream of the Analyzer.

• Do use ceramic or porous metallic type filters. Do not use cork or felt

filters.

JUNE 2008 Sample Systems Requirements

3-10 INSTALLATION AND SETUP

Pressure Regulators and Flow Controllers in Sample Line: Do not
use types containing cork or felt filters, or absorbent diaphragms.

Pipe Threads, Dressing: Do use Teflon tape. Do not use pipe thread
compounds (dope).

Valving:

• Install a block valve downstream of sample takeoff point for
maintenance and shutdown.

• Block valve should be gate valve or cock valve type, of proper material
and packing, and rated for process line pressure.

3.2 PREPARATION

3.2.1 Introduction

Model 1000A

Your Model 1000A Analyzer was started and checked out before it left the
factory. Program parameters were installed in the system and
documented in the “PC Config Report” furnished with your GC System.

3.2.2 Site Selection

Follow these guidelines for site selection:

• Provide adequate access space for performing maintenance and
adjustments.

- Allow a minimum of 3 feet (.9 m) in front for operator access.

- If possible, mount the Analyzer components in a vertical stack

configuration; it provides the greatest operator convenience.

Observe Precautions and Warnings

1

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

• Install the Analyzer as close as possible to the sample stream.

• Ensure that exposure to radio frequency (RF) interference is minimal.

PREPARATION JUNE 2008

Model 1000A

3.2.3 Unpacking the Unit

1

2

3

4

Observe the following checklist for unpacking the unit and
inspecting for damage:

1. Unpack the Model 1000A series Analyzer.

2. Ensure that all documentation and software are included:

(a) This manual, the Model 1000A Gas Chromatograph Hardware

Reference Manual, P/N 3-9000-750.

INSTALLATION AND SETUP 3-11

Observe Precautions and Warnings

Plan Site Location

Obtain Supplies and Tools

Install Analyzer Wiring

(b) The software manual, MON2000 Software for Gas

Chromatographs User Manual, P/N 3-9000-522.

(c) CD(s) with MON2000 and other GC applications.

Installation and startup of the GC should proceed only if all required
materials are on hand and free from obvious defects. If any parts or
assemblies appear to have been damaged in shipment, first file a claim
with the carrier. Next, complete a full report of the nature and extent of
the damage and forward the report immediately to Daniel Measurement
Services (DMS), a division of Emerson Process Management for further
instructions. Include complete model number information. Disposition
instructions will be returned immediately by Daniel Measurement
Services. Refer to the Customer Repair Report in the back of this manual.

JUNE 2008 Unpacking the Unit

3-12 INSTALLATION AND SETUP

3.2.4 Necessary Tools and Components

Observe Precautions and Warnings

1

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Observe the following checklist of tools and components that you
will need for installing the Analyzer and GC Controller:

1. Chromatographic grade carrier gas: zero grade helium, nitrogen
(99.995% pure, with less than 5 ppm water, and less than 0.5 ppm
hydrocarbons), argon, or hydrogen.

2. High pressure dual-stage regulator for the carrier gas cylinder, high
side up to 3000 pounds per square inch, gauge (psig), low side capable
of controlling pressure up to 150 psig.

Model 1000A

3. Calibration standard gas with correct number of components and
concentrations (see Section 2.1.6).

4. Dual-stage regulator for the calibration gas cylinder, low pressure side
capable of controlling pressure up to 30 psig.

5. Sample probe (fixture for procuring the stream, or sample gas for
chromatographic analysis).

6. 1/8-inch stainless steel (SS) tubing for connecting calibration standard
to analyzer, 1/4-inch SS tubing for connecting carrier to the analyzer,
1/8-inch SS tubing for connecting stream gas to the analyzer.

7. Miscellaneous Swagelok tube fittings, tubing benders and tubing
cutter.

8. 14 American Wire Gauge (AWG) (18 Metric Wire Gauge) or larger
electrical wiring and conduit to provide 115 or 230 volts AC, single
phase, 50 to 60 Hertz (Hz), from an appropriate circuit breaker and
power disconnect switch. See previous guidelines in Section 3.1.2.

9. Liquid leak detector (SNOOP

®

or equivalent).

10.Digital volt-ohm meter with probe-type leads.

Necessary Tools and Components JUNE 2008

Model 1000A

11.A flow measuring device such as Alltech Digital Flow Check™

Flowmeter.

3.2.5 Optional Tools and Components

Observe Precautions and Warnings

1

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Observe the following checklist of tools and components you may
need for installing and using the GC System:

1. For operation in a nonhazardous area only: Printer and printer paper.

INSTALLATION AND SETUP 3-13

2. For operation in a nonhazardous area only: An IBM-compatible PC

and a “straight-through” serial cable connection between the DB-9
(female) serial ports of the GC Controller and a serial port of the PC.
For details, see Section 3.4.2.

WARNING: SERIOUS INJURY OR DEATH POSSIBLE

Do not operate a PC or printer in a hazardous environment. Failure
to observe all safety precautions could result in serious injury or
death.

If you are working in a hazardous area and need to perform routine
operations, use the LOI that is built into the purged electronics
enclosure (see Section 4 this manual). To make more significant
program changes, however, use a remotely connected PC and the
software program MON2000. (See the MON2000 Software for Gas
Chromatographs User Manual, P/N 3-9000-522, for instructions on
operating the PC software, MON2000.)

(a) PC Specifications: Refer to Section 1.4.
(b) Serial Cable Specifications:

Straight-through serial cable with the following terminations:

DB-9, male, connects to GC’s serial port

DB-9 or DB-25, female, connects to PC serial port

JUNE 2008 Optional Tools and Components

3-14 INSTALLATION AND SETUP

3. Direct Serial Connect Cable, P/N 3-2350-068, to connect the PC or an
external modem directly to the one of the GC’s serial ports on the GC’s
Terminal Board for Field Wiring (TB). This cable comes in a
customer-specified length. It is terminated with a DB-9 female plug
at one end, for connection to a PC or external modem's serial port, and
six exposed leads at the other end for connection to the one of the GC's
serial ports on the TB.

4. Items necessary for connecting the GC to an external modem, a multi­drop serial network, or other type of remote data transfer system (an
example item might be an RS-232/RS-485 conversion box for long
distance serial transmission).

5. Ethernet connection (optional).

3.3 INSTALLING THE ANALYZER

3.3.1 Analyzer AC Power Wiring

Model 1000A

Observe Precautions and Warnings

1

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

To connect 115 volts AC-Power to the Analyzer, follow these
steps:

1. Locate the three leads for connecting 115 volts AC-power to the
Analyzer.

(a) Leads are "pig-tailed" from the Analyzer power supply through

conduit to a customer power NPT connection at the top of the
Analyzer stack.

(b) Leads are colored as follows:

HOT black

NEUTRAL white

GROUND green

INSTALLING THE ANALYZER JUNE 2008

Model 1000A

2. Connect Analyzer AC-power leads to properly controlled 115 volts AC-

INSTALLATION AND SETUP 3-15

power source (i.e., with circuit breaker and power disconnect switch).

WARNING: SERIOUS INJURY OR DEATH POSSIBLE

Do not connect AC power leads without first ensuring that AC power
source is switched OFF. Failure to observe all safety precautions
could result in serious injury or death.

(a) Make power line splices and conduit seals that comply with

applicable wiring requirements (for hazardous environments).

CAUTION: EQUIPMENT DAMAGE OR PERSONAL INJURY
Do not apply AC electrical power to the Analyzer until all electrical
power, interconnection, and external signal connections have been
verified, and proper grounds have been made. Failure to properly
connect the GC unit may result in serious equipment damage or
personal injury.

3. If necessary, connect the Analyzer's chassis ground to an external

copper ground rod (at remote locations). See Section 3.1.4 regarding
electrical and signal ground.

3.3.2 Sample and Gas Lines

To install GC sample and gas lines:

NOTE: Unless the sample stream is known to react with stainless
steel, use tubing of stainless steel construction. Keep tubing
internally clean and dry to avoid contamination. Before connection
the sample and gas lines, blow clean air or gas through them. Blow
out internal moisture, dust, etc.

1. Remove the plug from the Sample Vent (SV) line.

• If desired, connect the SV line to an external (ambient pressure)
vent. If the vent line is terminated in an area exposed to wind,
protect the exposed vent with a metal shield.

JUNE 2008 Sample and Gas Lines

3-16 INSTALLATION AND SETUP

• Use 1/4-inch or 3/8-inch tubing for vent lines longer than 10 feet.

Model 1000A

vent lines

Figure 3-1 Model 1000A Sample and Measure Vent Lines

Note that, at this stage in the installation, the GC Measure Vent (MV)
line remains plugged until leak checks are completed. For regular
operation, however, the MV line must be unplugged, or open.

Do not discard the vent line plugs. They are useful when leak­checking the GC and its sample and gas line connections.

2. Connect carrier gas to the GC. The carrier gas inlet is labelled
“Carrier In” and is a 1/8-inch T-fitting located on the left side of the
upper enclosure.

CAUTION: EQUIPMENT DAMAGE OR PERSONAL INJURY
Do not turn on gas until you have completed leak checking the carrier
and sample lines. Failure to follow this precaution may cause injury
to personnel or damage equipment.

Sample and Gas Lines JUNE 2008

Model 1000A

3. Connect sample gas stream(s) to the GC inlets located at the bottom of

INSTALLATION AND SETUP 3-17

• Use 1/8-inch or 1/4-inch stainless steel tubing to conduct carrier
gas.

• Use a dual-stage regulator with high-side capacity of 3000 psig and
low-side capacity of 150 psig.

• See Appendix C for a description of a dual-cylinder carrier gas
manifold (P/N 3-5000-050) with these features:.

- Carrier gas is fed from two bottles.

- When one bottle is nearly empty (100 psig), the other bottle

becomes the primary supply.

- Each bottle can be disconnected for refilling without

interrupting GC operation.

the lower enclosure.

sample stream

inlets

Figure 3-2 Sample Stream Inlets (Right side of unit)

• Use 1/8-inch or 1/4-inch stainless steel tubing to connect sample
gasses.

JUNE 2008 Sample and Gas Lines

3-18 INSTALLATION AND SETUP

• Ensure that pressure of sample line is regulated to maintain 15 to
30 psig (±10%).

After all lines have been installed, proceed with leak checking the
carrier and sample lines. See Section 3.5.1; note that it requires the
AC power to be turned on at the GC.

3.4 SETTING THE COM ID

The Model 1000A Com ID is determined by dual inline package (DIP)
switch settings.

NOTE: Follow the steps in this section only if you wish to change the
Com ID setting and visually inspect and verify the DIP switch
settings.

Model 1000A

Figure 3-3 Dip Switch

In most cases, the Com ID configuration made at the factory will not need
to be changed. The factory DIP switch settings produce a Com ID of 1.

3.4.1 Inspect or Change the Com ID

To visually inspect and verify the DIP switch settings or to change the
Com ID settings on the multifunction board, do the following:

1. Disconnect power to unit.

CAUTION: EQUIPMENT DAMAGE OR PERSONAL INJURY
Hazardous voltages present. Failure to properly disconnect the GC
unit may result in serious equipment damage or personal injury.

Setting the Com ID JUNE 2008

Model 1000A

2. Locate the multifunction board in the electronics enclosure. It is in the

INSTALLATION AND SETUP 3-19

lower left-hand corner.

multifunction
board

Figure 3-4 Location of the Multifunction board in the upper enclosure

JUNE 2008 Inspect or Change the Com ID

3-20 INSTALLATION AND SETUP

3. Unplug cables from multifunction board and driver I/O board.

4. Unscrew two fasteners holding multifunction board and digital I/O
board.

fasteners

multifunction

driver I/O
board

Model 1000A

board

Figure 3-5 Location of cables and fasteners

5. On the multifunction board, locate the Modbus slave address (Com ID)
DIP switch. It is labeled “S1” and mounted on the lower right corner of
the board.

Inspect or Change the Com ID JUNE 2008

Model 1000A

6. Inspect or change the DIP switch as necessary, using the wiring

INSTALLATION AND SETUP 3-21

Figure 3-6 Dip Switch

diagram as a guide (see Table 3-2).

• Make settings on switch S1 located on the multifunction board.

• Switches “1” through “5” form a 5-bit binary number for setting the
Modbus slave address (also known as Com ID or Device ID).

• Switch number “1” is the least significant bit, and switch number
“5” is the most significant bit. Set these switches either ON or OFF.

• Switch “6” and “7” are spares and switch “8” is used to cold start
the processor (see Table 3-3).

Use the GC maintenance records to document any changes made to
the switch settings.

Table 3-2 Modbus Slave Address (Com ID) DIP Switch Settings

Com ID 1 2 3 4 5

1 ON OFF OFF OFF OFF

2 OFF ON OFF OFF OFF

3 ON ON OFF OFF OFF

4 OFF OFF ON OFF OFF

5 ON OFF ON OFF OFF

6 SPARE

7 SPARE

8 COLD START

JUNE 2008 Inspect or Change the Com ID

3-22 INSTALLATION AND SETUP

Table 3-3 Switch Positions for Cold Start

Normal (Run) OFF

Cold Start ON

7. Reinstall the multifunction board and driver I/O board, making sure
to plug the cables into the proper receptacles.

3.4.2 Preparing for Serial Connections

The method for operating a Model 1000A system is from the LOI or a
connected personal computer. The PC must be:

• Running MON2000 software (version 2.2 or later). See the MON2000
User Manual (P/N 3-9000-522) for more information.

Model 1000A

8

• Connected to the Model 1000A via some form of communication link,
such as an optional ethernet or a serial connection.

This section addresses the basic ways to wire a serial connection between
a PC and the GC system.

Before connecting a PC to the Model 1000A, determine the following:

1. What serial ports are available at the PC?

When you select one, consider these points:

• Standard PC serial ports are type RS-232.

• Usually there are two external serial port jacks on a PC, located on

the rear panel. Most often, they are either DB-9 or DB-25 male (see
below).

NOTE: Model 1000A software upgrades can be installed through any
available COM port.

Preparing for Serial Connections JUNE 2008

Model 1000A

2. What serial ports are available at the GC?

INSTALLATION AND SETUP 3-23

• PC serial ports can be used by other peripheral equipment
attached to the PC, such as a printer, mouse, or modem, etc.

To determine which PC serial ports are already being used by
other equipment and which port can be used for connecting to the
GC, note existing serial connections, refer to your PC user manual,
and use diagnostic software (such as Norton Utilities).

The Model 1000A without the Micro-FID is equipped with three
serial ports. The installation of the optional Com4A board brings the
total number of available serial ports to six.

When you select a serial port, consider these points:

• Com1 and Com2 from the WinSystems CPU board (J1) to Field
Termination board (J5 and J7) (standard configuration)

• Com3 from WinSystems CPU board (J6) to the multifunction board

• Com4 from WinSystems CPU board (J6) to Field Termination
board

The Model 1000A with the Micro-FID comes equipped with two serial
ports (standard). The installation of the optional Com4A board bring the
total number of available serial ports to six.

When you select a serial port, consider these points:

• Com1 and Com2 from the WinSystems CPU board (J1) to Field
Termination board (J5 and J7) standard configuration

• Com3 from WinSystems CPU board (J6) to the multifunction board
(J4)

• Com4 from the WinSystems board (J6) is connected to the Micro­FID/TCD Preamplifier board (J4)

JUNE 2008 Preparing for Serial Connections

3-24 INSTALLATION AND SETUP

For additional serial ports, the:

• Optional Com4A board may be installed at the factory. Com5
through Com8 are fully available to the user and are factory­configured to RS-232 protocol. See Appendix A for additional
options (RS-422/485).

• With the optional Com4A board installed, six Com ports are
available to the user.

3. Is the connection to be made in a …

• Short distance between the PC and GC?

• With temporary or permanent cable connection?

See Section 3.4.3, FTB Connection (RS-232).

4. Is the connection to be made with a …

• Short distance between the PC and GC?

Model 1000A

• Permanent cable connection

See Section 3.4.4, PC to GC Cable Short Distance Connection (RS-232)

5. Is the connection to be made with a …

• Long distance between the PC and GC?

• Permanent cable connection

See Section 3.4.5, Long Distance Connection (RS-422, RS-485)

3.4.3 FTB Connection (RS-232)

The easiest way to connect a PC to the GC is with an off-the-shelf,
straight-through serial cable connected to the GC serial port DB 9-pin
connector pre-wired on the FTB.

1. Obtain a straight-through serial cable with these specifications:

• 50 feet long (or less)

• DB 9-pin or DB 25-pin female plug at one end (for PC connection)

• DB 9-pin male plug at the other end (for GC connection)

FTB Connection (RS-232) JUNE 2008

Model 1000A

NOTE: You can buy this cable from most computer supply retailers.
If, however, it is necessary to custom-wire a cable, see the guidelines
provided in Appendix B.

2. Connect the serial cable plugs to the appropriate serial port jacks at
the PC and GC. Use the MON2000 software to monitor and operate
the GC as needed.

3.4.4 PC to GC Cable Short Distance Connection (RS-232)

The PC-GC connection is made with straight-through serial cable
connected to one of the GC serial ports on the FTB.

NOTE: For detailed information concerning serial communications,
refer to Appendix A.

INSTALLATION AND SETUP 3-25

If the length of cable can be 50 feet or less, connect the serial cable to one
of the GC serial ports configured for RS-232. (Recall that output from a
standard PC serial port follows RS-232 serial definition.) Cable that is
longer than 50 feet, when used for RS-232 serial transmission, can result
in spurious loss or corruption of data.

To connect your PC to one of the Model 1000A serial port jacks, do the
following:

JUNE 2008 PC to GC Cable Short Distance Connection (RS-232)

3-26 INSTALLATION AND SETUP

1. Access the FTB, which is located to the right of the LOI in the
electronics enclosure.

Model 1000A

FTB

Figure 3-7 Field Termination Board

2. Choose an available serial port on the FTB that is configured for RS­232 protocol.

NOTE: The standard Model 1000A has three communications ports
available on the field termination board: Com1, Com2, and Com4.

Unless specified by the customer, serial ports are configured for RS-

232.

NOTE: Com4 is dedicated to the FID/TCD preamplifier.

PC to GC Cable Short Distance Connection (RS-232) JUNE 2008

Model 1000A

INSTALLATION AND SETUP 3-27

For further details, see Figure 3-8 and Figure 3-9.

Multifunction
Board

Com3

CPU

Com1
Com2
Com3
Com4

FID/TCD
Preamplifier Board

Com4

Field Termination
Board

Com1
Com2

Com5
Com6
Com7
Com8

Figure 3-8 Configuration without Com4A Board

Multifunction
Board

Com3

CPU

Com1
Com2
Com3
Com4

FID/TCD
Preamplifier Board

Com4

Field Termination
Board

Com1
Com2

Com4A

Com5
Com6
Com7
Com8

Com5
Com6
Com7
Com8

Figure 3-9 Configuration with Com4A Board

NOTE: Com4 is dedicated to the FID/TCD preamplifier.

JUNE 2008 PC to GC Cable Short Distance Connection (RS-232)

3-28 INSTALLATION AND SETUP

NOTE: With the Com 4A board installed, the Model 1000A has six
communications ports available on the FTB: Com1, Com2, Com5,
Com6, Com7, and Com8.

3. Connect the appropriate serial cable.

NOTE: See Appendix A for instructions on fabricating a direct serial
cable.

If using a direct 6 conductor serial cable, connect the exposed cable
leads to the FTB serial port. A pinout of a female DB 9-pin socket is
shown in Figure 3-10.

Model 1000A

Com1

P2

RI 1
DSR 1
RTS 1

RXD 1
CTS 1
TXD 1
DTR 1
DCD 1

GND

RI 2
DSR 2
RTS 2
RXD 2
CTS 2
TXD 2
DTR 2

DCD 2

5

9

4

8

3

7
2
6
1

Com2

P3

5
9

4
8
3
7
2
6
1

Figure 3-10 FTB Com1 and Com2 DB 9-pin Connector

PC to GC Cable Short Distance Connection (RS-232) JUNE 2008

Model 1000A

4. Field Termination Board serial communications settings are shown in

INSTALLATION AND SETUP 3-29

Figure 3-11 through Figure 3-15.

Com1

RS-232 RS-485 RS-422

DCD 1
RXD 1

TXD 1

TX/RX+
TX/RX- TX-

TX+

DTR 1

DSR 1
RTS 1

RX+
RX-

CTS 1
RI 1

J5

1
2
3
4

5

6

7

8
9

Figure 3-11 FTB Com 1 DB 9-pin Phoenix Connector

Com2

RS-232 RS-485 RS-422

DCD 2
RXD 2

TXD 2

TX/RX+
TX/RX- TX-

TX+

DTR 2

DSR 2
RTS 2

RX+
RX-

CTS 2
RI 2

J7

1
2
3
4

5

6
7
8

9

Figure 3-12 FTB Com2 DB 9-pin Phoenix Connector

JUNE 2008 PC to GC Cable Short Distance Connection (RS-232)

3-30 INSTALLATION AND SETUP

Model 1000A

Com5

RS-232 RS-485 RS-422

RLSD 5
RXD 5

TXD 5

TX/RX+
TX/RX- TX-

TX+

DTR 5

DSR 5
RTS 5

RX+
RX-

CTS 5

RI 5

J9

1
2
3
4

5

6
7
8

9

Figure 3-13 FTB Com5 DB 9-pin Phoenix Connector

Com6

RS-232 RS-485 RS-422

RLSD 6
RXD 6

TXD 6

TX/RX+
TX/RX- TX-

TX+

DTR 6

DSR 6
RTS 6

RX+
RX-

CTS 6

RI 6

J13

1
2
3
4

5

6
7
8

9

Figure 3-14 FTB Com6 DB 9-pin Phoenix Connector

PC to GC Cable Short Distance Connection (RS-232) JUNE 2008

Model 1000A

INSTALLATION AND SETUP 3-31

Com7

RS-232 RS-485 RS-422

RLSD 7

RXD 7
TXD 7

TX/RX+
TX/RX- TX-

TX+

DTR 7

DSR 7
RTS 7

RX+
RX-

CTS 7
RI 7

J17

1
2
3
4

5

6
7

8

9

Figure 3-15 FTB Com7 DB 9-pin Phoenix Connector

Com8

RS-232 RS-485 RS-422

RLSD 8
RXD 8

TXD 8

TX/RX+
TX/RX- TX-

TX+

DTR 8

DSR 8
RTS 8

RX+
RX-

CTS 8
RI 8

J18

1

2
3
4

5

6

7

8
9

Figure 3-16 Com8 DB 9-pin Phoenix Connector

GC Phoenix Plug Port

JUNE 2008 PC to GC Cable Short Distance Connection (RS-232)

3-32 INSTALLATION AND SETUP

Model 1000A

To make an RS-232 serial connection between one of the Phoenix Plug
serial ports of the GC, and an external modem with DB 25-pin serial port,
you will need to manufacture the cable and its DB 25-pin, male plug cable
end as illustrated below (see Figure 3-17).

Figure 3-17 GC Phoenix Plug Port to External Modem

DB 25-pin Port

3.4.5 Long Distance Connection (RS-422, RS-485)

RS-422 and RS-485 serial protocols are recommended for longer distance
serial connections between the PC and GC System (i.e., distances greater
than the 50 feet).

To connect your PC to one of the internal Model 1000A RS-422/RS-485
serial port jacks:

1. Obtain the following equipment:

• An asynchronous line driver (or interface device) with RS-232
input and RS-422/RS-485 output. See Appendix A for example
brand and model.

• Shielded, computer-grade, twisted pair cable (to connect the
asynchronous line driver device to the GC).

• A straight-through serial cable (to connect the PC to the line
driver).

Long Distance Connection (RS-422, RS-485) JUNE 2008

Model 1000A

2. Connect the straight-through serial cable from the PC serial port to

3. Configure the line driver for data communications equipment (DCE)

4. Access the FTB (see Figure 3-7 in Section 3.4.2).

5. Choose an available serial port on FTB that is configured for RS-422

INSTALLATION AND SETUP 3-33

the RS-232 serial port of the line driver device. Then connect the
twisted pair cable to the RS-422/RS-485 serial port of the line driver.

operation. See Appendix A for an example configuration.

or RS-485 serial protocol, and connect the twisted pair cable from the
line driver. See Appendix A for example connection. Also see Figure 3-

11 through Figure 3-15 for a list of ports and terminals assigned for

serial communications.

NOTE: Serial ports Com1, Com2, and Com3 are configured by
default for RS-232. For further details or instructions on how to
configure these ports to RS-422/485, see Appendix A.

3.4.6 Ethernet Connection (Optional)

Table 3-4 J1 PCM-NE2000 Ethernet Board Jumper Settings

Pin(s) Position

15 and 16 In

17 and 18 In

21 and 22 In

Table 3-5 J2 PCM-NE2000 Ethernet Board Jumper Settings

Pin(s) Position

1 and 2 In

JUNE 2008 Ethernet Connection (Optional)

3-34 INSTALLATION AND SETUP

Table 3-6 J3 PCM-NE2000 Ethernet Board Jumper Settings

3.4.7 GC-Printer Wiring

A printer can be connected directly to the GC the field termination board
(FTB) at one of the serial ports. The type and scheduling of reports
produced at the GC printer are determined by settings made in
MON2000 (from the Reports menu, select GC Report Request and/or GC
Printer Control; see the MON2000 Software for Gas Chromatographs
User Manual (P/N 3-9000-522) for more information).

Model 1000A

Pin(s) Position

1 and 2 In

7 and 8 In

NOTE: The GC uses a generic printer driver. The PC printer allows
more control and better quality output.

To connect a printer to the GC serial port, do the following:

1. Access the FTB (see Figure 3-7 in Section 3.4.2).

2. Choose an available serial port on the FTB that is configured for RS­232 serial protocol.

NOTE: See Appendix A for a complete listing of the serial ports and
corresponding pinouts to fabricate a serial printer cable.

3. After the wiring connections have been completed, use MON2000 to
configure the GC serial port.

(a) From the Application menu, select Serial Ports. The Serial Ports

window appears.

(b) Select the appropriate Port row and set Usage to “Report”, Protocol

to “ASCII” and RW to “W”.

(c) Ensure that the Com ID setting is correct.

GC-Printer Wiring JUNE 2008

Model 1000A

(d) Leave all other settings at the default values (see the MON2000

user manual for more information).

3.4.8 Discrete Digital I/O Wiring

The field termination board (P/N 3-0700-010) has five discrete outputs
and four discrete inputs. Refer to the MON2000 Software for Gas
Chromatographs Manual (P/N 3-9000-522) to configure the digital
outputs.

NOTE: To configure the digital output with MON2000, go to
Application
either normally open or normally closed.

→ User Defined → Selections and set EnableComAlm to

INSTALLATION AND SETUP 3-35

Discrete Digital Inputs

To connect digital signal input/output lines to the GC, do the following:

JUNE 2008 Discrete Digital I/O Wiring

3-36 INSTALLATION AND SETUP

1. Access the Field Termination Board (FTB) (P/N 3-0700-010).

J14

J10

Model 1000A

Figure 3-18 Field Termination Board

The FTB has five discrete outputs and four discrete inputs. The
discrete input, DIG_IN4, is dedicated to a pressure switch. The
discrete inputs are located on J10 (10 pin Phoenix connector).

2. Route digital I/O lines appropriately, especially in the case of the
explosion-proof enclosure.

There are connections for four digital inputs and five digital output
lines (Phoenix 10-pin connector), as follows:

Table 3-7 FTB Discrete Digital Inputs

J10 Function Description

Pin 1 DIG_IN1

Pin 2 GND

Pin 3 DIG_IN2

Pin 4 GND

Pin 5 DIG_IN3 to customer

Discrete Digital I/O Wiring JUNE 2008

Model 1000A

Discrete Digital Outputs

The discrete outputs are located on J14 (P/N 3-0700-010) (Phoenix 10-pin
connector) have two “Form A” relays on the FTB. Outputs 3-5 are Solid
State switches with a rating of .375A @30 VDC. The relays, with sealed
enclosures, have a contact current rating of 1.0 Amperes each (see Figure

3-18).

INSTALLATION AND SETUP 3-37

Table 3-7 FTB Discrete Digital Inputs

J10 Function Description

Pin 6 GND

Pin 7 DIG_IN4 dedicated to a pressure switch

Pin 8 GND dedicated to a pressure switch

Pin 9 DIG_IN5

Pin 10 GND

For discrete digital outputs, see Table 3-8.

Table 3-8 FTB Discrete Digital Outputs

J14 Function

Pin 1 DIG_OUT

Pin 2 DIG_OUT

Pin 3 DIG_OUT

Pin 4 DIG_OUT

Pin 5 DIG_OUT_ 3+

Pin 6 DIG_OUT_ 3-

Pin 7 DIG_OUT_ 4+

Pin 8 DIG_OUT_ 4-

Pin 9 DIG_OUT_ 5+

Pin 10 DIG_OUT_ 5-

JUNE 2008 Discrete Digital I/O Wiring

3-38 INSTALLATION AND SETUP

3.4.9 Analog Input Wiring

There are four analog inputs on the Field Termination Board (P/N 3­0700-010 and drawing CE-21157) located at J4 (12-pin Phoenix
connector).

Model 1000A

Table 3-9 FTB Analog Inputs

J4 Function

Pin 1 VIN+_1

Pin 2 VIN-_1

Pin 3 Shield

Pin 4 VIN+_2

Pin 5 VIN-_1

Pin 6 Shield

Pin 7 VIN+_3

Pin 8 VIN-_1

Pin 9 Shield

Pin 10 VIN+_4

Pin 11 VIN-_1

Pin 12 Shield

Analog Input Wiring JUNE 2008

Model 1000A

3.4.10 Analog Output Wiring

There are four standard analog outputs on the standard FTB (P/N 3­0700-010 and drawing CE-21157); located at J8 (12-pin Phoenix
connector). Additionally, if installed, the optional analog board has eight
analog outputs

Table 3-10 FTB Analog Outputs

INSTALLATION AND SETUP 3-39

J8 Function

Pin 1 IOUT+_1

Pin 2 IOUT-_1

Pin 3 Shield

Pin 4 IOUT+_2

Pin 5 IOUT-_2

Pin 6 Shield

Pin 7 IOUT+_3

Pin 8 IOUT-_3

Pin 9 Shield

Pin 10 IOUT+_4

Pin 11 IOUT-_4

Pin 12 Shield

There are eight analog outputs on the optional analog output board (P/N
2-3-0580-037 and drawing CE-21157); located at J3 (24-pin Phoenix
connector):

JUNE 2008 Analog Output Wiring

3-40 INSTALLATION AND SETUP

Table 3-11 Optional Analog Outputs

J3 Function

Pin 1 IOUT+_5

Pin 13 IOUT-_5

Pin 2 Shield

Pin 14 IOUT+_6

Pin 3 IOUT-_6

Pin 15 Shield

Pin 4 IOUT+_7

Pin 16 IOUT-_7

Model 1000A

Pin 5 Shield

Pin 17 IOUT+_8

Pin 6 IOUT-_8

Pin 18 Shield

Pin 7 IOUT+_9

Pin 19 IOUT-_9

Pin 8 Shield

Pin 20 IOUT+_10

Pin 9 IOUT-_10

Pin 21 Shield

Pin 10 IOUT+_11

Pin 22 IOUT-_11

Pin 11 Shield

Pin 23 IOUT+_12

Pin 12 IOUT+_12

Pin 24

Shield

Analog Output Wiring JUNE 2008

Model 1000A

3.4.11 Optional Boards

Optional modem boards are available for the Model 1000A GC.

The jumper settings and pinouts for each board is shown below.

Optional WinSystems Modem

Table 3-12 J8 Modem Board Jumper Settings

INSTALLATION AND SETUP 3-41

Pin(s) Position

1 and 2 In

3 and 4 In

5 and 6 In

7 and 8 In

Table 3-13 J9 Modem Board Jumper Settings

Pin(s) Position

1 and 2 In

5 and 6 In

Table 3-14 J10 Modem Board Jumper Settings

Pin(s) Position

1 and 2 In

3 and 4 In

5 and 6 In

9 and 10 In

15 and 16 In

JUNE 2008 Optional Boards

3-42 INSTALLATION AND SETUP

Optional Radicom Modem Settings

Table 3-15 J26 Radicom Modem Jumper Settings

Pin(s) Position

1 and 2 In

Table 3-16 J27Radicom Modem Jumper Settings

Pin(s) Position

1 and 2 In

Table 3-17 J30 Radicom Modem Jumper Settings

Pin(s) Position

1 and 2 In

Model 1000A

Table 3-18 J31 Radicom Modem Jumper Settings

Pin(s) Position

2 and 3 In

Optional Boards JUNE 2008

INSTALLATION AND SETUP 3-43

Model 1000A

3.5 ANALYZER LEAK CHECKS AND PURGING FOR FIRST CALIBRATION

3.5.1 Analyzer Leak Checks

Install Analyzer Wiring

4

Install Analyzer Sample & Gas

5

Lines

Install GC Controller Wiring

6

Perform Leak Checks

7

To perform Analyzer leak checks, follow these steps:

1. Plug the Measure Vent (labeled "MV") vent line if it is open. (The

"SV", or Sample Vent line should be left open, or unplugged.)

2. Slowly pressurize each line in turn, then block-in the line, making

sure the pressure holds. For example, the carrier gas line should be
slowly brought up to 110 psig (±2 percent) with the dual-stage
regulator at the gas cylinder.

3. After 2 minutes, shut the carrier gas bottle valve and observe the

high-side regulator gauge.

(a) The gauge should not bleed down more than 100 psig in 10

minutes.

(b) If the carrier gas is lost at a faster rate, leaks are usually found

between the carrier gas bottle and the Analyzer. Check and
tighten all connections, as well as the dual-stage regulator.

4. When the leak check is complete, reopen the carrier gas bottle valve.

Remove the plug from the MV line.

5. Repeat the procedure with sample gas and stream gas after first

shutting the metering valve below the rotameter on the front of the
Flow Panel. The metering valve is left shut for now

, but will be
reopened later during initial purging and the Analyzer's first
calibration.

JUNE 2008 ANALYZER LEAK CHECKS AND PURGING FOR FIRST CALIBRATION

3-44 INSTALLATION AND SETUP

3.5.2 Purging Carrier Gas Lines

Perform Leak Checks

7

Purge Carrier Gas Lines

8

Purge Calibration Lines

9

Model 1000A

10

CAUTION: EQUIPMENT DAMAGE OR PERSONAL INJURY

Purging carrier and calibration gas lines will require that AC power
be turned on to the Analyzer. Ensure that unit interconnections and
all external signal connections have been verified, and proper
grounds have been made. Failure to verify all connections may result
in equipment damage or personal injury.

NOTE: Tubing should be clean and dry internally. During
installation use compressed air to remove moisture, dust, or other
contaminants from all tubing.

Start Up GC System

To purge the carrier gas lines, as preparation for first
calibration, follow these steps:

1. Ensure that the "MV" vent line plug has been removed, and the vent
line is open.

Purging Carrier Gas Lines JUNE 2008

Model 1000A

2. Turn on the AC power to the Analyzer. The LOI will turn on.

INSTALLATION AND SETUP 3-45

Figure 3-19 Analyzer components

JUNE 2008 Purging Carrier Gas Lines

3-46 INSTALLATION AND SETUP

3. Using the LOI or MON2000, ensure that all of the Analyzer valves are
set to the AUTO position.

4. Ensure that the carrier gas bottle valve is open.

5. Using the LOI or MON2000, set the calibration gas stream (Stream 2
by default) to the “ON” position.

NOTE: Do not use the "Carrier Pressure Adjust" valve (on the Flow
Panel of the Analyzer) to adjust carrier gas line pressure. That valve
is factory-set and should not be adjusted.

3.5.3 Purging Calibration Gas Lines

Perform Leak Checks

7

Purge Carrier Gas Lines

8

Model 1000A

Purge Calibration Lines

9

10

Start Up GC System

To purge the calibration gas lines, as preparation for first
calibration, follow these steps:

1. Ensure that the carrier gas lines have been fully purged, as described
in the previous section.

2. Close the calibration gas bottle valve.

3. Fully open the block valve associated with calibration gas feed (the
block valve should be located on the SCS plate of the Analyzer).

4. Fully open the metering valve (on the Flow Panel, below the
rotameter).

5. Open the electronics enclosure to access the valve driver board.

6. On the valve driver board, upper enclosure, set the Stream switch "S2"
to MAN (if Stream 2 will be used for calibration gas).

7. Open the calibration gas bottle valve.

Purging Calibration Gas Lines JUNE 2008

Model 1000A

8. At the calibration gas bottle regulator, increase outlet pressure to 20

psig, ±5%.

9. Close the calibration gas bottle valve.

10.Let both gauges on the calibration gas bottle valve bleed down to 0

(zero) psig.

11.Repeat steps (7) through (10) five times.

12.Open the calibration gas bottle valve.

13.Regulate the flow through the rotameter to approximately 50 cubic

centimeters per minute (cc/min) by adjusting the metering valve on
the Flow Panel.

14.To prepare for normal operation, set the calibration gas stream switch

(Stream 2 by default) to AUTO using the LOI or MON2000.

3.6 SYSTEM START-UP

INSTALLATION AND SETUP 3-47

Perform Leak Checks

7

Purge Carrier Gas Lines

8

Purge Calibration Lines

9

Start Up GC System

10

To perform system start-up, follow these steps:

1. For system startup, run an analysis of the calibration gas.

(a) If equipped with an optional stream switching board, ensure that

the stream switch for the calibration stream is set to AUTO.

Otherwise, ensure that the calibration gas supply is turned on and
set to the correct pressure (25 to 30 PSIG).

(b) Use MON2000 to run a single stream analysis on the calibration

stream. Once proper operation of the GC is verified, halt the
analysis by selecting Control → Calibration and Control → Halt.
See the MON2000 Software for Gas Chromatographs User Manual
(P/N 3-9000-522) for more information.

JUNE 2008 SYSTEM START-UP

3-48 INSTALLATION AND SETUP

2. Start Auto Sequence of the line gas stream(s) by selecting Control →
Auto Sequence. See the MON2000 Software for Gas Chromatographs
User Manual for more information. The GC will begin the Auto

Sequence analysis mode.

Model 1000A

SYSTEM START-UP JUNE 2008

MAINTENANCE AND TROUBLESHOOTING 4-1

Model 1000A

4--

MAINTENANCE AND TROUBLESHOOTING

4.1 HAZARDOUS ENVIRONMENTS

WARNING: EQUIPMENT DAMAGE OR PERSONAL INJURY

Observe all precautionary signs posted on the Model 1000A
enclosure. Failure to do so can result in injury or death to personnel
or cause damage to the equipment.

WARNING: EQUIPMENT DAMAGE OR PERSONAL INJURY

The Model 1000A enclosures are rated for a general purpose area.
The enclosures are certified by CSA for Class I Division 2 Groups B,
C, and D locations, Temperature Code T3 with an optional Type Z
purge.

Special conditions for safe use must be met. The maximum
constructional gap (ic) is less than that required by Table 1 of IEC
60079-1:2004 as detailed in the Table 4-1 below.

Before opening the Model 1000A assembly, reduce the risk of igniting
hazardous atmospheres by disconnecting the equipment from all
power supplies. Keep the assembly closed tightly when in operation
to reduce the risk of igniting hazardous atmospheres.

Inlet (incoming) wiring must meet local standards (i.e. in conduit
with seal fitting within 18” or via cable glands certified to IEC 60079-

1). Seal all unused entries with blanks certified to IEC 60079-1.

Please direct all health, safety and certification related questions to:
Emerson Process Management, Gas Chromatographs, Applications
Engineering Group, 713-827-6380 or 1-866-GC Center (1-866-422-

3683).

Table 4-1 Flamepath Fitting Tube Gap Safety

FLAMEPATH MAXIMUM GAP (MM) COMMENT

Fitting tube adaptor/fitting tube taper 0.000 Taper fit

Fitting tube/taper/tubes 0.132

JUNE 2008 Hazardous Environments

4-2 MAINTENANCE AND TROUBLESHOOTING

4.2 TROUBLESHOOTING AND REPAIR CONCEPT

The most efficient method for maintaining and repairing the Model
1000A GC system is a component-replacement concept that allows you to
return the system to operation as quickly as possible. Sources of trouble,
such as printed-circuit assemblies, valves, etc., are identified during trou­bleshooting test procedures and are replaced at the lowest level practical
with units in known working order. The defective components are then
either repaired in the field or returned to Measurement Services for
repair or replacement.

4.3 ROUTINE MAINTENANCE

The Model 1000A GC system will perform accurately for long periods
with very little attention (except for maintaining the Carrier Gas
cylinders). A bimonthly record of certain parameters will assist greatly in
assuring that your Model 1000A is operating to specifications. The
maintenance checklist should be filled out bimonthly, dated, and kept on
file for access by maintenance technicians as necessary (see Table 4-

2).This gives you a historical record of the operation of your Model 1000A,

enables a maintenance technician to schedule replacement of gas
cylinders at a convenient time, and allows quick troubleshooting and
repair when it becomes necessary.

Model 1000A

A chromatogram, a Configuration Report, and a Raw Data Report should
also be made and filed with the checklist, furnishing a positive dated
record of the Model 1000A. The chromatogram and reports can also be
compared to the chromatograms and reports run during the troubleshoot­ing process.

4.3.1 Bimonthly Maintenance Checklist

Copy the sample maintenance checklist as necessary for your files (see

Table 4-2). If you have a problem, please complete the checklist and

reports, and have the results available when calling Measurement
Services with a problem. Also have the Sales Order number. The Sales
Order number can be found on the nameplate located on the left side wall

Troubleshooting and Repair Concept JUNE 2008

MAINTENANCE AND TROUBLESHOOTING 4-3

Model 1000A

of the upper housing of the Model 1000A. The chromatograms and reports
archived when your Model 1000A left the factory are filed by this number.

Table 4-2 Maintenance Checklist

Date Performed: Sales Order Number:

System Parameters As Found As Left Nominal

Carrier Gas Cylinder

Cylinder Pressure Reading (High)
Cylinder Pressure Outlet Reading

Carrier Pressure Panel Regulator ____ psig N/A 85 psig

Sample System

Sample Line Pressure(s) (1)____ psig ____ psig 20 psig

Sample Flows (1)___ cc/min ____cc/min 40-60 cc

Sample Vent 1 (SV1) (2)___ cc/min ____cc/min 40-60 cc

Sample Vent 2 (SV2) (3)___ cc/min ____cc/min 40-60 cc

____ psig

____ psig

(2)____ psig ____ psig 20 psig

(3)____ psig ____ psig 20 psig

(4)____ psig ____ psig 20 psig

(5)____ psig ____ psig 20 psig

(4)___ cc/min ____cc/min 40-60 cc

(5)___ cc/min ____cc/min 40-60 cc

____ psig

____ psig

____ psig

110 psig

Calibration Gas

High Pressure Reading ____ psig ____ psig

Outlet Pressure Reading ____ psig ____ psig 20 psig

Flow ____ cc/min ___ cc/min 40-60 cc

JUNE 2008 Bimonthly Maintenance Checklist

4-4 MAINTENANCE AND TROUBLESHOOTING

4.3.2 Routine Maintenance Procedures

• Complete the maintenance checklist bi-monthly. Place the sales order
number, date, and time on the form and file it. This gives you a basis
for comparison in the future if you need it.

• Save a Chromatogram of the operating Model 1000A on the PC with
the MON 2000 software. Print Configuration, Calibration, and Raw
Data reports and file them with the MON 2000.

• Check the printer paper (if used) to ensure that a sufficient supply of
paper remains. Check carrier and calibration gas supplies.

4.3.3 Contact Service

Measurement Services offers maintenance service programs that are
tailored to fit specific requirements. Contracts for service and repair can
be arranged by contacting Measurement Services at the address or
telephone number on the Customer Repair Report at the back of this
manual.

Model 1000A

4.4 ACCESS TO GC EQUIPMENT ELEMENTS

4.4.1 Electrical/Electronic Components

WARNING: EQUIPMENT DAMAGE OR PERSONAL INJURY

The electronics enclosure should not be opened when the unit is
exposed to an explosive environment. If access to the eletronics
enclosure is required, precautions must be taken to ensure that an
explosive environment is not present. Failure to do so may result in
injury or death to personnel or cause damage to the equipment.

The Model 1000A electrical/electronic components are located in the
electronics enclosure. All of the electrical/electronic components are fully
accessible from the front of the GC.

Routine Maintenance Procedures JUNE 2008

Model 1000A

MAINTENANCE AND TROUBLESHOOTING 4-5

Figure 4-1 Model 1000A electronics enclosure, front view

Model 1000A with TCD Electronics Enclosure•

• Multifunction Board

• Dual Methods Adapter Board

• Dual Methods Preamplifier Board

• Solenoid Heater/Driver Board

• WinSystems CPU Board

•Analog Board

• Com4A Board (optional)

• Ethernet Board (optional)

• Radicom Modem board (optional)

• DC/DC Field Termination Board

JUNE 2008 Electrical/Electronic Components

4-6 MAINTENANCE AND TROUBLESHOOTING

• Eight Channel Analog (non-isolated 4-20mA) Output Board (optional)

• Four Channel Analog (isolated 4-20mA) Output Board (optional)

Model 1000A with Micro-FID/TCD Electronics Enclosure

• Multifunction Board

• Solenoid/Heater Driver Board

• FID/TCD Preamplifier Board with ADC

• FID/TCD Preamplifier Power Supply Board

• FID Connector Board

• Field Termination Board

•Backplane Board

• Interconnect Board

Model 1000A

• WinSystems CPU (with PC104 interface)

• Com4A PC/104 Board (optional)

• Ethernet Board (optional)

• Radicom Modem Board (optional)

NOTE: The optional Radicom Modem is always mounted on top of
the PC/104 card stack.

• Eight Channel Analog (non-isolated 4-20mA) Output Board (optional)

• Four Channel Analog (isolated 4-20mA) Output Board (optional)

• Front Panel Analytical and Stream Switch Panel

Electrical/Electronic Components JUNE 2008

Model 1000A

• Dual Methods Adapter Board

MAINTENANCE AND TROUBLESHOOTING 4-7

Figure 4-2 CPU, Com4A, and Modem Boards

NOTE: The optional Ethernet board is not shown, but plugs into the
CPU board or the Com4A board.

4.4.2 Detector Elements, Heater Elements, Valves and Columns

The detector elements, heater elements, valves and columns are located
in the air bath oven located in the enclosure directly beneath the
eletronics housing.

Figure 4-3 Air bath oven

JUNE 2008 Detector Elements, Heater Elements, Valves and Columns

4-8 MAINTENANCE AND TROUBLESHOOTING

The detector elements, including the FID, are each located in a seperate
housing inside the air bath oven.

Model 1000A

TCD housing

Figure 4-4 TCDs and valves

Figure 4-5 TCD element located in its housing inside the air bath oven

valve

Detector Elements, Heater Elements, Valves and Columns JUNE 2008