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MODEL 51 OOA
CO ANALYZER
Instruction Bulletin
IB-106510A
Rev. 2.1
ROSEMOUNT”ANALYTICA1
FISHEfkRBSEMOUNT”Managing
The Process Better:
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HIGHLIGHTS OF CHANGES
Effective November, 1997 Rev. 2.0
PAGE
l-2
1-3
2-12
2-13
3-6
3-l
6-13
8-29
9-2
9-3
9-4
10-l Changed the European address.
I-3
SUMMARY
Added RS-232 information to control module description in paragraph 1.2.
Added RS-232 information to performance specifications in paragraph l-4.
Added RS-232 interface option to Figure 2-12.
Added RS-232 information to paragraph 2-&b.(g).
Added RS-232 information to control module description in paragraph 3-2.d
Added RS-232 interface option to Figure 3-7.
Added RS-232 information to paragraph 6-6~1.
Added rear interface PC board callout to Figure 8.35.
Added RS-232 I&U interface control module to Table 9-2. Updated solenoid/dual gas assembly
part number in Table 9.2.
Added slider port and chopper motor w/solenoid/dual gas cell assembly in Table 9.4. Updated
existing chopper motor and solenoid dual/gas cell part numbers in Table 9.4.
Added RS-232 rear interface control module to Table 9-S Updated existing rear interface control
module in Table 9-5.
Added RS-232 to index.
Effective November, 1998 Rev. 2.1
PAGE SUMMARY
3-13 Added step (a)(3) to Audible Alarm paragraph 3-3x.3.
3-43 Changed terminal numbers in paragraphs 3.g.c.l.(c) and 3-8x.4.(c).
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ROSEMOUNT WARRANTY
Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be free of
defects in workmanship or material. Should any failure to conform to this warranty become apparent during
a period of one year after the date of shipment, Rosemount shall, upon prompt written notice from the
purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts.
Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount with
respect to the quality of the equipment.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER
WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IMPLIED (INCLUDING
ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR PURPOSE).
The remedy(ies) provided above shall be purchaser’s sole remedy(&) for any failure of Rosemount to
comply with the warranty provisions, whether claims by the purchaser are based in contract or in tort
(including negligence).
Rosemount does not warrant equipment against deterioration due to environment. Factors such as
corrosive gases and solid particulates can be detrimental and can create the need for repair or replacement
as part of normal wear and tear during the warranty period.
Equipment supplied by Rosemount Analytical Inc., but not manufactured by it, will be subject to the
same warranty as is extended to Rosemount by the original manufacturer.
At the time of installation it is important that the required services are supplied to the system and that
the electronic controller is set up at least to the point where it is controlling the sensor heater. This will
ensure, that should there be a delay between installation and full commissioning that the sensor being
supplied with ac power and reference air will not be subjected to component deterioration.
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PURPOSE
The purpose of this manual is to provide a comprehensive understanding of the Model 5100A CO
Analyzer, components, functions, installation, and maintenance.
This manual is designed to provide information about the Model 5lOOA CO Analyzer. We recommend
that you thoroughly familiarize yourself with the Overview and Installation sections before installing your
analyzer.
‘Ike overview presents the basic principles of the Model 5loOA CO Analyzer along with its performance
characteristics and components. The remaining sections contain detailed procedures and information
necessary for installation and servicing of the Model 5100A CO Analyzer.
Before contacting Rosemount concerning any questions, first consult this manual. It describes most
situations encountered in your equipment’s operation and details necessary action.
DEFINITIONS
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this
publication.
NOTE
Highlights an essential operating procedure,
condition, or statement.
NOTE TO USERS
The number in the lower right comer of each illustration in this publication
is a manual illustration number. It is not a part number and is not related to the
illustration in any technical manner.
IB-106.510A
ii
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IMPORTANT
SAFETY INSTRUCTIONS FOR THE WIRING AND
INSTALLATION OF THIS APPARATUS
The following safety ioslxoctions apply specifically to all EU
member states. They should be strictly adhered to in order to
assure compliance with the Low Voltage Directive. Non-EU
states should also comply with the following unless superseded
by local or National Standards.
1. Adequate earth connections should be made to all earthing points, internal and external, where provided,
2. After installation or troubleshooting, all safety,covers and safety grounds must be replaced. The integrity of
all earth terminals must be maintained at all times.
3. Mains supply cords should comply with the requirements of IEC227 or IEC2.45
4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C
5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage.
6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a
circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit
breaker may also include a mechanically operated isolating switch. If not, then another means of
disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers
or switches must comply with a recognized standard such as IEC947. All wiring must conform with any
local standards.
7. Where equipment or covers are marked with the symbol to the right, hazardous voltages
are likely to be present beneath. These covers should only be removed when power is
removed from the equipment - and then only by trained service personnel.
8. Where equipment or covers are marked with the symbol to the right, there is a danger
from hot surfaces beneath. These covers should only be removed by trained service
personnel when power is removed from the equipment. Certain surfaces may remain hot
to the touch.
9. Where equipment or covers are marked with the symbol to the right, refer to the
Operator Manual for instructions.
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10. All graphical symbols used in this product are from one or more of the following standards: EN61010-1,
IEC417, and IS03864.
IB-lLb551iM
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BELANGRIJK
Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel.
De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lid&ten. Hier moet aan
gebouden worden om de onderworpenheid aan de Laag Spannings Ricbtlijn (Low Voltage Directive) te
verzekeren. Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijn
door plaatselijke of nationale voorschriften.
1.
Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten, intern en extem.
2.
Na install& of controle moeten alle veiligheidsdeksels en -aardingen temg geplaatst worden. Ten alle tijde
moet de betrouwbaarheid van de aarding behouden blijven.
3.
Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC245 voorschriften.
4.
Alle bekabeling meet geschikt zijn voor het gebroik in omgevingstemperatoren, hoger dan 75°C.
5.
Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd is.
6.
Om de veilige werking van dit to&e1 te verzekeren, meet de voeding door een stroomonderbreker gevoerd
worden (min 10A) w&e & draden van de voeding meet onderbreken. De stroomonderbreker mag een
mechanische schakelaar bevatten. Zoniet meet een andere mogelijkheid bestaan om de voedingsspanning
van het toestel te halen en ook duidelijk zo zijn aangegeven. Stroomonderbrekers of schakelaars moeten
onderworpen zijn aan een erkende standaard zoals IEC947.
I.
Waar toestellen of deksels aangegeven staan met het symbool is er meestal hoogspanning
aanwezig. Deze deksels mogen e&l verwijderd worden nadat de voedingsspanning werd
afgelegd en enkel door getraind onderhoudspersoneel.
8.
Wax toestellen of deksels aangegeven staan met het symbool is er gevaar voor hete
oppervlakken. Deze deksels mogen enkel verwijderd worden door getraind
onderhoudspersoneel nadat de voedingsspanning verwijderd werd. Sommige opppervlakken konnen 45 minuten later nog steeds heet aanvoelen.
9.
Waar toestellen of deksels aangegeven staan met het symbool gel&e het handboek te
raadplegen.
10. Alle grafische symbolen gebruikt in dit produkt, zijn atkomstig uit een of meer van devolgende standaards;
EN61010-1, IEC417 en ISO3864.
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VIGTIGT
Sikkerhedsinstruktion for tilslutning og installering af dette udstyr.
F0lgende sikkerhedsinstruktioner gaelder specifikt i alle EU-medlemslande. Instruktionernc skal n0je
f0lges for overholdelse af Lavsspaendingsdirektivet og h0r ogsH f0lges i ikke EU-lande medmindre andet er
specificeret af lokale eller nationale standarder.
1. Passende jordforbindelser skal tilsluttes alle jordklemmer, inteme og eksteme, hvor disse forefindes.
2. Efter installation eller fejlfinding skal alle sikkerhedsdreksler og jordforbindelser reetableres.
3. Forsyningskabler skal opfylde krav specificeret i IEC227 eller IEC245.
4. Alle ledningstilslutninger skal vaxe konstmeret til omgivelsestemperatar h@jere end 75” C.
5. Alle benyttede kabelforskmninger skal have en~intem dimension, si passende kabelafIastning kan etableres.
6. For opnMse af sikker drift og betjening skal der skabes beskyttelse mod indirekte bergring gennem afbryder
(min. lOA), som vi1 afbryde & kredsl@b med elektriske ledere i fejlsitua-tion. Afbryderen skal indholde en
mekanisk betjent kontakt. Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes og
mzerkes som shdan. Afbrydere eller kontakter skal overholde en kendt standard som IEC947.
7. Hvor udstyr eller dreksler er maerket med dette symbol, er farlige sp=ndinger normalt
forekom-mende bagved. Disse dzksler b#r kun afmonteres, nti forsyningssplendingen er
frakoblet og da kun af instmeret servicepersonale.
8. Hvor udstyr eller dreksler er maerket med dette symbol, forefindes meget varme
overfIader bagved. Disse daeksler b@r kun afmonteres af instrueret servicepersonale, nti
forsyningsspznding er frakoblet. Visse overflader vi1 stadig vwe for varme at ber@re i
op ti145 minutter efter fmkobling.
9. Hvor udstyr eller daeksler er maxket med dette symbol, se da i betjeningsmanual for
instmktion.
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10. Alle benyttede grafiske symboler i dette udstyr fmdes i Cn eller flere af fglgende standarder EN61010-1,
IFC417 & IS03864.
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BELANGRIJK
Veiligheidsinstructies voor de bedrading en installatie van dit apparaat.
Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de geldende
richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden. Ook niet EU lidstaten
dienen zich aan het volgende te houden, tenzij de lokale wetgeting anders voorschrijft.
1.
Alle voorziene inteme- en exteme aardaansluitingen dienen op adequate wijze aangesloten te worden.
2.
Na installatie,onderhouds- of reparatie werkzaamheden dienen alle beschermdeksels ikappen en aardingen
om reden van veiligheid weer aangebracht te worden.
3.
Voedingskabels dienen te voldoen aan de vereisten van de normen IEC 227 of JEC 245.
4.
Alle bedrading dient~geschit te zijn voor gebmik bij een omgevings temperatour boven 75°C.
5.
Alle gebroikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een adequate verankering
van de kabel wordt verkregen.
6.
Om een veilige werking van de apparahmr te waarborgen dient de voeding uitsluitend plaats te vinden via
een meerpolige automatische zekering (min.lOA) die g& spanningvoerende geleiders verbreekt indien een
foutconditie optreedt. Deze automatische zekering mag ook voorzien zijn van een mechanisch bediende
schakelaar. Bij het ontbreken van deze voorziening dient een andere als zodanig duidelijk aangegeven
mogelijkheid aanwezig te zijn om de spanning van de apparatuur af te schakelen. Zekeringen en schakelaars
dienen te voldoen aan een erkende standaard zoals IEC 947.
I.
Wax de apparahmr of de beschermdeksels/kappen gemarkeerd zijn met het volgende
symbool, kmmen zich hieronder spanning voerende delen bevinden die gevaar op kunnen
leveren. Deze beschermdeksels/kappen mogen uitsluitend verwijderd worden door
getraind personeel als de spanning is afgeschakeld.
8. Waar de apparahmr of de beschenndekselsflcappen gemarkeerd zijn met het volgende
symbool, kmmen zich hieronder hete oppervlakken of onderdelen bevinden. Bepaalde
delen kmmen mogelijk na 45 min. nog te heet zijn om aan te &en.
9. Wax de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende
symbool, dient men de bedieningshandleiding te raadplegen.
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10. Alle grafische symbolen gebmikt bij dit produkt zijn volgens een of meer van de volgende standaarden:
EN 61010-1, IEC 417 & IS0 3864.
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Turvailisuusohje, jota on noudatettava t&n511 l&teen asentamisessa ja kaapeloinnissa.
Seuraavat ohjeet piiteviit erityisesti EU:n jlisenvaltioissa. Niitii tiytyy ehdottomasti noudattaa jotta
t5ytettSisiin EUm matalaj%mitedirektiivin (Low Voltage Directive) yhteensopivuus. My& EU:hun
kuulumattomien valtioiden tulee nowdattaa titii ohjetta, elleivtit kansalliset standardit esti sit%
1.
RiittWtt maadoituskytkenn?it on tehMv% kaikkiin maadoituspisteisiin, sis%isiin ja ulkoisiin.
2.
Asennuksen ja vianetsinntin jglkeen on kaikki suojat ja suojamaat asennettava takaisin pai-koilleen.
Maadoitusliittimen kunnollinen toiminta tiiytyy aina yllZpit~%
3.
Jtinitesy&t6johtimien f&ytyy t?iytt&? IEC227 ja IEC245 vaatimukset.
4.
Kaikkien johdotuksien tulee toimia >75”C 18impijtiloissa.
5.
Kaikkien lapivientiholkkien sistialkaisijan fiytyy olla sellainen ettX kaapeli lukkiutuu kun-nolla kiinni.
6.
Turvallisen toiminnan varmistamiseksi t%ytyy j%nnitesyBttB varustaa huvakytkimell% (min lOA), joka kytkee
irti kaikki jtinitesytittiijohtimet vikatilanteessa. Suojaan tiytyy my& sis%lty% mekaaninen erotuskytkin. Jos
ei, niii jtinitesy6tt6 on pystyttiivti katkaisemaan muilla keinoilla ja merkitt&+i siten ett% se tunnistetaan
sellaiseksi. Turvakytkimien tai kat-kaisimien tgytyy ttiytm IEC947 standardin vaatimukset n%kyvyydest%
I.
Mii%li laite tai kosketussuoja on merkitty till% merkilti on me&inn& t&ma tai alla
hengenvaarallisen suuruinen jsnnite. Suojaa ei saa poistaa jinniteen ollessa kytkettyns
laitteeseen ja poistamisen saa suorittaa vain alan asian-hmtija.
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8.
Mikai laite tai kosketussuoja on merkitty til8: merkills on me&inn& takana tai alla
kuuma pinta. Suojan saa poistaa vain alan asianhmtija kun j&mite-syiittij on katkaista.
Tgllainen pinta voi s%ilyi kosketaskuumana jopa 45 mi-nuuttia.
9.
Mik%li laite tai kosketassuoja on merkitty ttiti merkillii katso lisiiohjeita kiiytteohjekirjasta
10. Kaikki t&X tuotteessa Hytetyt graafiset symbolit ovat yhdestii tai useammasta seuraavis-ta standardeista:
EN61010-1, IEC417 & IS03864.
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IMPORTANT
Consignes de s&wit6 concernant le raccordement et l’installation de cet appareil.
Les consignes de s&wit6 ci-dessous s’adressent particali~rement A tow les hats membres de la
communaut6 europ6enne. Elles doivent iXre strictement appliqks afin de satisfaire aux directives
concernant la basse tension. Les kats non membres de la communautk europ6enne doivent hgalement
appbquer ces conslgnes saaf SI elles sent en contradiction avec les standards locaux ou nationaux.
1.
Un raccordement adgquate a la terre doit &tre effectuke ?I chaque borne de mise a la terre, inteme et exteme.
2.
Apr&s installation ou dkpannage, tous les capots de protection et mutes les prises de terre doivent &tre remis
en place, toutes les prises de terre doivent &tre respect&s en permanence.
3. Les &bibles d%mentation &ctrique doivent &re conformes aux normes IEC227 ou IEC245
4.
Tous les raccordements doivent pouvoir supporter one tempCratore ambiante sup&ieure 2 75°C.
5. Tous les presse-Moupes utilisCs doivent avoir un diam&re inteme en rapport avec les csbles afin d’assurer
un serrage correct sur ces demiers.
6.
Afin de garantir la s&u&? do fonctionnement de cet appareil, le raccordement a l’alimentation Sxtrique
doit &tre r&lid exclusivement au travers d’un disjonctenr (minimum lOA.) isolant tout les conducteurs en
cas d’anomalie. Ce disjoncteur doit kgalement pouvoir &tre actionng manuellement, de faGon mkmique.
Dans le cas contraire, un autre syst&ne doit &re mis en place afin de pouvoir isoler I’appareil et doit &re
signalis& comme tel. Disjoncteurs et intermpteurs doivent &tie conformes Bone norme reconnue telle
IEc947.
7. Lorsque les kquipements ou les capots affichent le symbole suivant, cela signifie que des
tensions dangereuses sent prkntes. Ces capots ne doivent &tre d&non& que lorsque
I’alimentation est coupke, et uniquement par on personnel compttent.
8. Lorsque les Lquipements ou les capots affichent le symbole suivant, cela signifie que des
surfaces dangereusement chaudes sent prkentes. Ces cap&s ne doivent &tre d&monk& qoe
lorsque l’alimentation est coupLe, et uniquement par on personnel comp&ent. Certaines
surfaces peuvent rester chaudes jusqu’k 45 mn.
9. Lorsque les Cquipements ou les capots affichent le symbole suivant, se reporter au manuel
d’instroctions.
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10. Tous les symboles graphiques utilids dans ce produit sent conformes g on ou plusieurs des standards
suivants: EN61010-l.lEC417 & ISO3864.
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Wichtip:
Sicherheitshinweise filr den Anschlul3 und die Installation dieser Gergte.
Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europtischen Gemeinschaft giiltig.
Sie miissen strickt eingehalten werden, urn der Niederspannungsriehtlinie zu geniigen.
Nichtmitgliedsstaaten der europiiischen Gemeinschaft sollten die national giiltigen Normen and
Richtlinien einhalten.
1. Alle intern und extem vorgesehenen Erdungen der Geri%e miissen ausgefiihrt werden.
2. Nach Installation, Reparatur oder sonstigen Eingriffen in das Gerit miissen alle Sicherheitsabdeckungen und
Erdungen wieder installiert werden. Die Funktion aller Erdverbindungen darf zu keinem Zeitpunkt gestiirt
sein.
3. Die Netzspannungsversorgung mu8 den Anfordemngen der IEC227 oder IEC245 geniigen.
4. Alle Verdrahtongen sollten mindestens bis 75 “C ihre Fur&ion dauerhaft efillen.
5. Alle Kabeldurchfiihrungen und Kabelverschraubungen sollten in Ihrer Dimensionierung so gewtilt werden,
daU diese eine sichere Verkabehmg des Gerstes ermiiglichen.
6. Urn eine sichere Funktion des GerXtes zu gewtirleisten, mu0 die Spannungsversorgung iiber mindestens 10
A abgesichert sein. Im Fehlerfall mu13 dadurch gewtirleistet sein, daf3 die Spannungsversorgung zum Gertit
bzw. zu den Ger&ten unterbrochen wird. Ein mechanischer Schutzschalter kann in dieses System integriert
werden. Falls eine derartige Vorrichtung nicht vorhanden ist, mu!3 eine andere Maglichkeit zur
Unterbrechung der Spannungszufuhr gewtirleistet werden mit Hinweisen deutlich gekennzeichnet werden.
Ein solcher Mechanismus zur Spannungsunterbrechung mu!3 mit den Normen und Richtlinien fir die
allgemeine Installation van Elektrogerzten, wie zum Beispiel der lEC947, iibereinstimmen.
7. Mit dem Symbol sind Gergte oder Abdeckungen gekennzeichnet, die eine geftirliche
(Netzspannung) Spannung fiihren. Die Abdeckungen dtien nor entfernt werden, wenn
die Versorgungsspannung unterbrochen worde. NW geschultes Personal darf an diesen
Gersten Arbeiten ausfihren.
8. Mit dem Symbol sind GerXte oder Abdeckungen gekennzeichnet, in bzw. unter denen
heiBe Teile vorhanden sind. Die Abdeckungen d&fen nor entfernt werden, wenn die
Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen
Geriten Arbeiten ausfiihren. Bis 45 Minuten nach dem Unterbrechen der Netzzufuhr
kannen derartig Teile noch iiber eine erh6hte Temperatur verfiigen.
9. Mit dem Symbol sind GerXte oder Abdeckungen gekennzeichnet, bei denen vor dem
Eingriff die entsprechenden Kapitel im Handbuch sorgfgltig
mtissen.
10. Alle in diesem Gerit verwendeten graphischen Symbole entspringen einem oder mehreren der nachfolgend
aufgefihrten Standards: EN61010-1, IEC417 & IS03864.
durchgelesen werden
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IMPORTANTE
Norme di sicurezza per il cablaggio e I’installazione dello strmnento.
Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell’Unione Europea, la cui
stretta osservanza 6 richiesta per garantire conform&$ alla Direttiva de1 Basso Voltaggio. Esse si applicano
anche agli stati non appartenenti all’unione Europea, salvo quanta disposto dalle vigenti normative locali
0 nazionali.
1.
Collegamenti di terra idonei devono essere eseguiti per tutti i punti di messa a terra intemi ed estemi, dove
previsti.
2.
Dopo l’installazione o la localizzazione dei guasti, assicurarsi the tutti i coperchi di protezione siano stati
collocati e le messa a terra siano collegate. L’integriti di ciscun morsetto di terra deve essere costantemente
garantita.
3.
I cavi di alimentazione della fete devono essere second0 disposizioni IEC227 o IEC2.45.
4.
L’intero impianto elettrico deve essere adatto per use in ambiente con temperature superiore a 75°C.
5.
Le dimensioni di totti i connettori dei cavi utilizzati devono essere tali da consentire un adeguato ancoraggio
al cave.
6.
Per garantire un sicuro funzionamento dell0 stmmento il collegamento alla rete di alimentazione principale
dovrk essere eseguita tramite intenvttore automatic0 (min.lOA), in grade di disattivare tutti i conduttori di
circuito in case di guasto. Tale intenuttore dovr& inoltre prevedere un sezionatore manuale o altro
dispositivo di interruzione dell’alimentazione, chiaramente identificabile. Gli interruttori dovranno essere
conformi agli standard riconosciuti, quali IEC947.
7.
11 simbolo riportato sullo strumento o sui coperchi di protezione indica probabile presenza
di elevati voltaggi. Tali coperchi di protezione devono essere rimossi esclusivamente da
personale qualificato, dopo aver tolto alimentazione allo stmmento.
8.
I1 simbolo riportato ~110 strumento o sui coperchi di protezione indica rischio di contatto
con superfici~ad alta temperatora. Tali coperchi di,protezione devono essere rimossi
esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento.
Alcune super&i possono mantenere temperature elevate per oltre 45 minuti.
9. Se lo strumento o il coperchio di protezione riportano il simbolo,
fare riferimento alle istmzioni de1 manuale Operatore.
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10. Tutti i simboli grtici utilizzati in questo prodotto sono previsti da uno o pib dei seguenti standard:
EN61010-1. IEC417 e IS03864.
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VIKTIG
Sikkerhetsinstruks for tllkobling og installasjon av dette utstyret.
F0lgende sikkerhetsinstraksjoner gjelder spesilikt alle EU medlemsland og land med i E@S-avtalen.
Instruksjonene skal f@lges n#ye slik at installasjonen blir i henhold til lavspennlngsdirektivet. Den b@r
ogs& ffdges i andre land, med mindre annet er spesifisert av lokale- eller nasjonale standarder.
1. Passende jordforbindelser m% tilkobles alle jordingspunkter, inteme og eksteme hvor disse forefinnes,
2. Etter installasjon eller feilsgking skal alle sikkerhetsdeksler og jordforbindelser reetableres.
Jordingsforbindelsene nG alltid holdes i god stand.
3. Kabler fra spenningsforsyning skal oppfylle kravene spesifisert i IEC227 eller IEC245.
4. Alle ledningsforbindelser skal were konstmert for en omgivelsestemperator hoyere en 750C.
5. Alle kabelforskmvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig avlastning oppnies.
6. For i oppni sikker drift og betjening skal forbindelsen til spenningsforsyningen bare skje gjennom en
strembryter (minimum 1OA) som vi1 bryte spenningsforsyningen til alle elektriske kretser ved en
feilsituasjon. Strplmbryteren kan ogsi inneholde en mekanisk operert bryter for L isolere instmmentet fra
spenningsforsyningen. Dersom det ikke er en mekanisk operert bryter installert, rni det were en annen mite
?I isolere utstyret fra spenningsforsyningen, og denne mitten rni wre tydelig merket. Kretsbrytere eller
kontakter skal oppfylle kravene i en annerkjent standard av type” IEC947 eller tilsvarende.
7. Der hvor utstyr eller deksler er merket med symbol for farlig spenning, er det sannsynlig
at disse er tilstede bak dekslet. Disse dekslene rni bare fjaemes nti spenningsforsyning
er frakoblet utstyret, og da bare av trenet servicepersonell.
8. Der hvor utstyr eller deksler er merket med symbol for meget varm overflate, er det
sannsynlig at disse er tilstede bak dekslet. Disse dekslene m&bare fjlemes II&
spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell. Noen
overflater kan were for varme til B bereres i opp ti145 minutter etter spenningsforsyning
frakoblet.
9. Der hvor utstyret eller deksler er merket med symbol, vennligst referer til
instmksjonsmanualen for instmkser.
1
l
A
10. Alle grafiske symboler brukt i dette produktet er fra en eller flere av f@lgende standarder: EN61010-1,
IEC417 & IS03864.
Page 16
IMPORTANTE
Instru@es de seguranqa para ligqiio e instala@o desk aparelho.
As seguintes instru@es de seguranga aplicam-se especificamente a todos OS estados membros da UE.
Devem ser observadas rigidamente por forma a garantir o cmnprimento da Directiva sobre Baixa Ten&o.
Relativamente aos estados que n5o pertengam B UE, deverSio cumprir igualmente a referida directiva,
exceptuando OS cases em que a legisla@o local a tiver substitaido.
1.
Devem ser feitas liga@es de terra apropriadas a todos OS pontos de terra, intemos ou extemos.
2.
Ap6s a instala@o ou eventual repara@o, devem ser recolocadas todas as tampas de seguransa e terras de
protec@o. Deve manter-se sempre a integridade de todos OS terminais de terra.
3. OS cabos de alimenta@o elktrica devem obedecer is exigEncias das normas IEC227 ou IEC2.45.
4. OS cabos e fios utilizadosnas liga@es elktricas devem ser adequados para utiliza@o a uma temperatura
ambiente ati 75” C.
5.
As dimensdes intemas dos buck dos cabos devem ser adequadas a uma boa fixaGio dos cabos.
6.
Para assegurar urn funcionamento seguro deste equipamento, a liga@o ao cabo de alimentaqzo ektrica
dew ser feita atrav6 de urn disjuntor (min. 1OA) que desligara todos OS condutores de circuitos durante uma
avaria. 0 disjuntor poderA tamb&n canter urn interruptor de isolamento accionado manualmente. Caso
contrkio, deveri ser instalado qualquer outro meio para desligar o equipamento da energia ektrica,
devendo ser assinalado convenientemente. OS disjuntores ou interruptores devem obedecer a uma norma
reconhecida, tipo IEC947.
I. Sempre que o equipamento ou as tampas contiverem o simbolo, 6 prov&vel a existkcia de
tens6es perigosas. Estas tampas s6 devem ser retiradas quando a energia elktrica tiver
sido desligada e por Pessoal da Assist&ncia devidamente treinado.
8. Sempre que o equipamento ou as tampas contiverem o simbolo, hi perigo de existencia de
superficies quentes. Estas tampas s6 devem ser retiradas por Pessoal da Assistikcia
devidamente treinado e depois de a energia ektrica ter sido desligada., Algumas
superficies permanecem quentes at& 45 minutes depois.
9. Sempre que o equipamento ou as tampas contiverem o sfmbolo, o Manual de
Funcionamento deve ser consultado para obten@o das necesstiias instru@es.
t
a
A
10. Todos OS simbolos grificos utilizados neste produto baseian-se em uma ou mais das seguintes normas:
EN61010-1, IEC417 e IS03864.
Page 17
IMPORTANTE
Instrocciones de segurldad para el montaje y cableado de este aparato.
Las sigoientes instnxciones de seguridad , son de aplicacion especlfica a todos 10s miembros de la UE y se
adjuntaran para cmnplir la normativa europea de baja tension.
1. Se deben preveer con&ones a tierra de1 equipo, tanto extema coma intemamente, en aquellos terminales
previstos al efecto.
2. Una VW. finalizada las operaciones de mantenimiento de1 equipo, se deben volver a colocar las cubiertas de
seguidad aasi coma 10s terminales de t&a. Se debe comprobar la integridad de cada terminal.
3. Los cables de alimentacion electrica cumpliran con las normas IEC 227 o lEC 245
4. Todo el cableado sera adecuado para una temperatura ambiental de 75°C.
5. Todos 10s prensaestopas seran adecuados para una fijacion adecuada de 10s cables
6. Para un manejo seguro de1 equipo, la alimentacion electrica se realizara a traves de un interruptor
magnetotennico ( min 10 A ), el cual desconectara la alimentacion electrica al equip0 en todas sus fases
durante un fallo. Los interruptores estaran de acuerdo a la norma IEC 947 u otra de reconocido prestigio,
7. Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica peligrosa,
dicho alojamiento solamente se abrira una vez que se haya intemunpido la alimentacion
electrica al equip0 asimismo la intervention sera llevada a cabo por personal entrenado
para estas labores.
8. Cuando las tapas o el equipo lleve impreso el simbolo, hay superficies con alta
temperatura, por tanto se abrira una vez que se haya interrumpido la alimentacion
electrica al equip0 por personal entrenado para estas labores, y al menos se esperara
unos 45 minutes para enfriar las supetficies calientes.
9. Cuando el equipo o la tapa lleve impreso el simbolo, se consultara el manual de
instrucciones.
t
.
A
10. Todos 10s simbolos graficos usados en esta hoja, estan de acuerdo alas siguientes normas EN61010-1,
IEC417 & IS0 3864.
Page 18
VIKTIGT
Siikerhetsfdreskrifter fiir kablage och installation av denna apparat.
FSljande s%kerhetsfiireskrifter sir tilliimpliga fdr samtliga EU-medlemsl%nder. De skall fdljas i varje
avseende fiir att iiverensstima med LHgspZmdngs direktivet. Icke EU medlemsltinder skall ocks~ fdlja
nedanstiende punkter, Aida de inte iivergrips av lokala eller nationella fdreskrifter.
1.
TillWplig jordkontakt skall utf6ras till alla jordade punkter, s%l intemt som extemt dti si erfordras.
2.
Efter installation eller fels&ning skall samtliga stierhetshtiljen och s&erhetsjord &xplaceras. Samtliga
jordterminaler mLte h&s obrutna hela tiden.
3.
Matningssptiningens kabel mbte Gverensst%mma med Mreskriftema i lEC227 eller lEC245.
4.
Allt kablage skall vara l%mpligt f6r anv?indning i en omgivningstemperatur hBgre &I 75°C.
5.
Alla kabelfiirskmvningar som anvbds skall ha inre dimensioner som motsvarar adekvat kabelfiirankring.
6.
F6r att s?&erst%lla s&er drift av denna utmstning skall anslutning till huvudstr&nnen endast giiras genom en
sgkring (min 1OA) som skall fr?mkoppla & str&nf&ande kretsar n%r &got fel uppsfir. S%kringen kan given
ha en mekanisk f&skiljare. Om sz? inte %r fall&, mhte ett annat fiirfarande f& att frtiskilja utmstningen
f&n striimfiirsijrining tillhandah%las och klart framgi venom marker&z. S&rina eller omkopplare maste
Gverenssttima Led-en g%llande standard sLom t ex &947.
- -
I.
DXr utmstning eller hBlje %I markerad med vids&nde symbol Mreliggerisk fi% livsfarlig
sptining i r&h&en. Dessa hBljen f& endast avl%gsnas n%ir st&nmen ej %r an&ten till
utrostningen - och di endast av utbildad servicepersonal.
8.
Nti utmstning eller h6lje %I markerad med vidstiende symbol fijreligger risk f&
br&mskada vid kontakt med uppvinnd yta. Dessa h6ljen f% endast avl%gsnas av utbildad
servicepersonal, nti stri%nmen kopplats frh utmstningen. Vissa ytor kan vara mycket
varma att vidrijra iven upp till 45 minuter efter avstigning av striimmen.
NL utmstning eller h6lje markerats med vids&nde symbol b6r instruktionsmanualen
9.
studeras fijr information.
10
Samtliga gmfiska symboler som fijrekommer i denna prod& firms angivna i en eller flera av fiiljande
f&eskrifter:- EN61010-1, IEC417 & ISO3864.
A
III
A
t
.
A
Page 19
10. oh0 Ta ypocptK6 ~ti@Ao mu Xptjqtonototiat oc
wqxoo6~Spa 0116 ?a &rg npbnma: EN61010-1, IEC417 Kat 1503864.
IB-106.510A
mhoi
am6
TO npoi6v hat on6 &vo ft
Page 20
Page 21
TABLE OF CONTENTS
Section
Rosemount Warranty.. ...................................................................................................................................................
I. GENERAL DESCRIPTION AND SPECIFICATIONS
Introduction ..............................................................................................................................................
l-1.
Description ...............................................................................................................................................
1-2.
Operation..
1-3.
Performance Specifications ......................................................................................................................
1-4.
l-5. Physical Specifications.. ...........................................................................................................................
l-6. Utilities Specifications .............................................................................................................................
II. INSTALLATION
2-l. General .....................................................................................................................................................
2-2. Unpacking and Inspection.. ......................................................................................................................
2.3. Site Selection and Preparation ..................................................................................................................
Infrared Receiver Module Installation ......................................................................................................
2.4.
2.5. Infrared Source Module Installation
Flue Gas Temperature Probe Installation .................................................................................................
2.6.
Control Module Installation
2.1.
Electrical Installation.. ..............................................................................................................................
Z-8.
Purge Air Requirements ...........................................................................................................................
2-9.
.
OPERATIONS AND CONTROLS
3-l. Theory of Operation .................................................................................................................................
3-2. Description of Major Components
Infrared Source Module
Flue Gas Temperature Probe .................................................................................................................
Infrared Receiver Module .....................................................................................................................
Purge Air/Enclosure Assembly ..........................................................................................................
Radiometer Assembly ........................................................................................................................
Power Supply Board ..........................................................................................................................
CPU Board .........................................................................................................................................
Control Module.. ...................................................................................................................................
3-3. Description of Controls ............................................................................................................................
lR Receiver Module Controls ...............................................................................................................
IR Source Temperature Controller Controls
ALIGN/RUN Switch (Sl)
Intensity Adjustment Potentiometer (R18).
lR Source Temperature Controller Controls
Temperature Setpoint Potentiometer ..................................................................................................
Control Module.. ...................................................................................................................................
Control Module Display-Upper Display ............................................................................................
Audible Alarm.. ..................................................................................................................................
................................................................................................................................................
.........................................................................................................
.....................................................................................................................
...........................................................................................................
........................................................................................................................
.........................................................................................
..................................................................................................................
........................................................................................
.........................................................................................
Control Module Display-Lower Display..
Keyboard.. ..........................................................................................................................................
..........................................................................................
Page
2-13
3-10
3-11
3-13
3-13
i
l-l
l-l
1-2
1-3
l-3
1-5
2-1
2-l
2-l
2-2
2-6
2-8
2-9
2-9
3-1
3-4
3-4
3-6
3-6
3-6
3-6
3-6
3-6
3-6
3-8
3-8
3-9
3-8
3-8
3-9
3-9
3-9
Page 22
TABLE OF CONTENTS (Continued)
Section
3-4. Keyboard
3-5. CO Computation .......................................................................................................................................
3-6. Function Listing and Description ..............................................................................................................
3-7. Function Security System .........................................................................................................................
3-X.
3.9. Peek and Poke System Memory ................................................................................................................
3-10. How to Change Addresses in Function
3-l 1. How to Enter Data into an Address in Function 60 (Peek & Poke) ..........................................................
Page
Functions.. ................................................................................................................................
STORE ENTRY Key ............................................................................................................................
[*I
Decimal Point/RBSP TIME Key..
O/GAS TEMP Key .................................................................................................................................
COKE Key.. ..........................................................................................................................................
l/CAL/OFF Key ....................................................................................................................................
2lSET ZERO Key ..................................................................................................................................
3lRANGE Key .......................................................................................................................................
2nd KEY/NEXT Key
4lHOLDlOFF Key.. ...............................................................................................................................
5lSAVE
6lRBSTORE n Key ................................................................................................................................
USER KEY/PROGRAM Key ...............................................................................................................
IlDlAGNOSE Key
S/ALARM
g/ALARM 2 Key
ACK ALARM/ENABLE/OFF Key .......................................................................................................
Secondq Functions ..............................................................................................................................
Hold Command.. ....................................................................................................................................
Hold Flag..
User Locked Function Security .............................................................................................................
Factory Locked Function Security
System Cahbratmn ....................................................................................................................................
Zero Calibration Cycle ..........................................................................................................................
Automatic Calibration Cycle
The Hexadecimal Number System
The Hexadecimal System Used by the 5100
n Key.. .....................................................................................................................................
1 Key.. .................................................................................................................................
.............................................................................................................................................
..
............................................................................................................................
................................................................................................................................
...................................................................................................................................
.................................................................................................................
....................................................................................................
.........................................................................................................
........................................................................................................
.........................................................................................
60 (Peek&Poke). .......................................................................
3-14
3.14
3.15
3-16
3-17
3.17
3-18
3-19
3-20
3-21
3-22
3-25
3.26
3-21
3-28
3.30
3-30
3-31
3.32
3-38
3-38
3-38
3-38
3-38
3-39
3.39
3.40
3-41
3-41
3-41
3-48
3-49
3-50
Iv.
V.
STARTUP AND CALIBRATION
4-l. General .....................................................................................................................................................
4.2. Pre-Operation Check and Control Settings
4-3. Optical Alignment. ....................................................................................................................................
4.4. Initialize Control Module .........................................................................................................................
4.5. Zero Calibration ........................................................................................................................................
ACCESSORIES
5-l. Interconnect Cable ....................................................................................................................................
5.2. Thermocouple wire.. ................................................................................................................................
5-3. Source Purge Air Assembly ......................................................................................................................
Theory of Operation
Source Purge Air Assembly with Jet Pumps.
Source Purge Air Assembly with Blower..
..............................................................................................................................
...............................................................................................
.........................................................................................
............................................................................................
4-l
4-1
4-l
4-2
4-6
5-l
5-l
5-l
5-l
5-l
5-3
Page 23
TABLE OF CONTENTS
(Continued)
S&iOll
VI. CIRCUIT DESCRIPTIONS
6-l
Overview.. ................................................................................................................................................
6-2
Temperature Control (Source) ..................................................................................................................
6-3
Receiver CPU (Central Processor Unit) ...................................................................................................
Description.. ..........................................................................................................................................
CPU Section
Watch Dog Section ...............................................................................................................................
Memory Section.. ..................................................................................................................................
Address Decoder Section
J/O Section ............................................................................................................................................
Analog Section.. ....................................................................................................................................
6-4
Receiver Power Supply Board .................................................................................................................
AC Voltage
Tl Secondary Voltage.. .........................................................................................................................
AC Voltage ...........................................................................................................................................
Solenold Trutcs ......................................................................................................................................
Tnac Clrcult for Calibration Source. .....................................................................................................
6-5
Control Module CPU ...............................................................................................................................
Description.. ..........................................................................................................................................
CPU Section ..........................................................................................................................................
Watch Dog Section ...............................................................................................................................
Memory Section.. ..................................................................................................................................
Decoder Section. ...................................................................................................................................
II0 Section
6-6
Control Module Output Circuit Board
Components Not Used in Output Generation
Circuit Operation ...................................................................................................................................
6-7
Control Module Power Supply.. ...............................................................................................................
Tl Transformer .....................................................................................................................................
Alarm Sections ......................................................................................................................................
..........................................................................................................................................
...........................................................................................................................................
..
............................................................................................................................................
Page
......................................................................................................................
.....................................................................................................
........................................................................................
6-l
6-l
6-l
6-l
6-3
6-3
6-3
6-3
6-3
6-6
6-6
6-9
6-9
6-9
6-9
6-9
6-9
6-9
6.12
6-12
6-12
6.12
6-13
6-13
6.13
6-16
6-17
6.17
6-17
VII. TROUBLESHOOTING
7-l. Diagnostics Program ................................................................................................................................
7-2. Fault/Error Alert.. .....................................................................................................................................
Fault Flag ..............................................................................................................................................
Audible Alarm.. ..................... . ...............................................................................................................
Alarm 3 .................................................................................................................................................
Held Output Flag.. .................................................................................................................................
Hold Flag
Receiver Startup.. ..................................................................................................................................
7-3. Fault/Error Identification ..........................................................................................................................
GelleW.1.. ................................................................................................................................................
Fault Overrides ......................................................................................................................................
7-4. Fault/Error Description ............................................................................................................................
1-S. Troubleshooting .......................................................................................................................................
..............................................................................................................................................
7-l
7-l
7-l
7-l
7-l
7-l
7-1
7-2
7-2
7-2
l-2
7-2
7-3
Page 24
TABLE OF CONTENTS (Continued)
Section
7-6. General
7-7. Guidelines for Fault Codes .......................................................................................................................
7-8. Limits on
7-9. To Peek at Address 0000 ..........................................................................................................................
7-10. To Peek at Address 0007.. ........................................................................................................................
7-l 1. To Peek at Addresses 0001 and
Troubleshooting of Faults
Flow Chart
Symbols ..............................................................................................................................
...........................................................................................................
Flow Chart Abbrevntlons .....................................................................................................................
Flow Chart
Footnotes ............................................................................................................................
More Than One Action in an Action Block.. .........................................................................................
References Made to Addresses in the Memory .....................................................................................
Multiple Faults ......................................................................................................................................
Fault Code 1 ..........................................................................................................................................
Fault Code 2 ..........................................................................................................................................
Fault Code 3 ..........................................................................................................................................
Fault Code 4
..........................................................................................................................................
Fault Code 5 ..........................................................................................................................................
Fault Code 6
Fault Code
..........................................................................................................................................
7 ..........................................................................................................................................
Fault Code 8 ..........................................................................................................................................
Fault Code
9 ..........................................................................................................................................
Fault Code 10 ........................................................................................................................................
Fault Code 11 ........................................................................................................................................
Fault Code 12 ........................................................................................................................................
Fault Code 13 ........................................................................................................................................
Fault Code 14
Troubleshooting System (Receiver) Reset..
........................................................................................................................................
...........................................................................................
Voltages and
Resistances.. ........................................................................................................
.....................................................................................................
OOOZ..
Page
l-6
l-6
7-6
7-6
7-10
7-10
7-10
7.10
7-11
7-11
7-11
7-11
7-11
7.12
7-12
7-12
7-12
7.13
7-13
7.13
7-13
7-13
l-35
7-36
7-31
7-31
7-38
VIII. SERVICE AND NORMAL MAINTENANCE
8.1. Overview ..................................................................................................................................................
8-2.
Removal of Source from Stack/Duct.. ......................................................................................................
8.3.
Removal of PCB from Source
..................................................................................................................
8.4. Installation of PCB Assembly to Source.. .................................................................................................
8-5.
Source Test
Procedure.. ............................................................................................................................
Coil, Ohmic Value Test (Source) ..........................................................................................................
Overall Source Voltage Test of Thermocouples ....................................................................................
Function Test (Source) ..........................................................................................................................
8.6. Installation of Source
8.7. Thermocouple Test Procedure
................................................................................................................................
..................................................................................................................
Procedure A ...........................................................................................................................................
Procedure
B ...........................................................................................................................................
8.8. Removal/Installation of Radiometer .........................................................................................................
8.9. Detector Installation Procedure ................................................................................................................
X-10. Dark Level Test of Possible Noisy Detector.. ...........................................................................................
8-l 1. Test and Replacement of Speed Sensor
....................................................................................................
Speed Sensor Test .................................................................................................................................
Removal of Speed Sensor from Radiometer
Installation of Speed Sensor to Radiometer..
..........................................................................................
.........................................................................................
8-l
8-J
8-2
8-4
8-5
8-5
8-5
8-6
8-7
8-7
8-8
8-8
8-10
8-12
S-15
8-16
S-16
8-16
8-17
Page 25
TABLE OF CONTENTS (Continued)
section
8-12. Removal of Dual Gas Cells with Solenoid
8-13.
8- 14. Removal of the Calibration Gas Cell.. ......................................................................................................
8-15. Installation of the Calibration Gas Cell
8-16. Removal, Installation of Chopper
8-17. Test of Chopper.. ......................................................................................................................................
S-18. Removal/Installation of the Calibration Source
8.19. Receiver CPU Board Replacement..
8-20.
8.21. Calibration of Control Module Output Card
8-22. Reference Voltage Adjustment..
S-23.
8.24. Board Replacement ..................................................................................................................................
8-25. Cleaning of Calcium Fluoride Window ....................................................................................................
8.26. Record Keeping.. ......................................................................................................................................
8-27. Manual Check of Span Response
8.28. History Log
Page
...............................................................................................
Installation of Dual Gas Cell Assembly.. ..................................................................................................
....................................................................................................
Motor.. ................................................................................................
Removal of Chopper Motor ..................................................................................................................
Installation of Chopper Motor.. .............................................................................................................
........................................................................................
Removal of the Calibration
Installation of the Calibration Source.. ..................................................................................................
Control Module CPU Board Replacement.. .............................................................................................
Receiver Alignment Procedure.. ...............................................................................................................
Apply Power to the Infrared Source Module
Optical Alignment
Removal and Installation of Control Module
Power Supply Board .......................................................................................................................
Removal and Installation of the Control Module
Output Circuit Board .......................................................................................................................
Removal and Installation of Control Module
Rear Interface Circuit Board ...........................................................................................................
Removal and Installation of Receiver Power
Supply Circuit Board (PCB) ...........................................................................................................
Removal and Installation of the
...............................................................................................................................................
.................................................................................................................................
Source .......................................................................................................
.........................................................................................................
............................................................................................
...............................................................................................................
.........................................................................................
Receiver Ribbon
.............................................................................................................
..................................................................
Cable..
S-17
8-19
8-21
8-22
8-22
8-22
8-23
8-24
8-25
8-25
8-26
8-27
8-28
g-30
8-32
8-33
8-33
8-33
X-34
8-34
8-35
8-35
8-37
8-37
8-38
8-38
8-39
8-39
Ix. REPLACEMENT PARTS
X. RETURNING EQUIPMENT TO THE FACTORY
INDEX
Page 26
LIST OF ILLUSTRATIONS
Figure
l-l.
2-l.
2-2.
2-3.
2.4.
2-5.
2-6.
2.1.
2-8.
2-9.
2-10.
2.11.
2-12.
3-l.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
5-l.
5-2.
6-l.
6-2.
6-3.
6-4.
6-5.
6.6.
6-7.
6-S.
6-9.
7-l.
7-2.
7-3.
1.4.
7-5.
7-6.
7-7.
7-8.
7-9.
7-10.
7.11.
7-12.
7-13.
7.14.
7-15.
7-16.
7-17.
Page
Typical Model 5 100 CO Analyzer System
Outline and Mounting Dimensions, Infrared Receiver Module with Jet Pump ........................................
Outline and Mounting Dimensions, Infrared Receiver Module
with Purge Air Blower Hose Adapter
Infrared Receiver Module Installation with Jet Pump ...............................................................................
Infrared Receiver Module Installation with Hose Adapter .......................................................................
Outline and Mounting Dimensions, Infrared Source Module ...................................................................
Infrared Source Module Installation .........................................................................................................
Flue Gas Temperature Probe Installation .................................................................................................
Control Module Installation.. ....................................................................................................................
Electical Installation ................................................................................................................................
Purge Air Pressure and Flow Requirements for Model 5 100 CO Analyzer.. ............................................
Outline and Mounting Dimensions, Purge Air Blower Motor ..................................................................
Blower Motor Wiring Connections
Spectral Transmittance of CO2 and CO
Optical Mounting.. ....................................................................................................................................
optical components
Primary Signal Processing -- Analog Representation ...............................................................................
Signal Processing Block Diagram -- Analog Representation ....................................................................
IR Source and Receiver Modules Block Diagram
Control Module Block Diagram ...............................................................................................................
IR Receiver Module Controls ...................................................................................................................
IR Source Module Temperature Controller ..............................................................................................
Control Module Display
Control Module Keyboard.. ......................................................................................................................
Source Purge Air Assembly with Jet Pumps
Source Purge Air Assembly ......................................................................................................................
Main Source Temperature Control Schematic ..........................................................................................
Receiver CPU Circuit Card Schematic .....................................................................................................
Detector Output (Waveform TP- 13) Receiver Card CPU Board ..............................................................
Receiver Power Supply Schematic ...........................................................................................................
Control Module CPU Circuit Card Schematic ..........................................................................................
Control Module Output Circuit Card Schematic
Duty Cycle (TPl). .....................................................................................................................................
Control Module Power Supply Circuit Card
Deleted
Multiple Faults Flowchart. ........................................................................................................................
Source Temperature Flowchart .................................................................................................................
Flue Gas Temperature Flowchart. .............................................................................................................
Radiometer Temperature Flowchart .........................................................................................................
Cold Junction Temperature Flowchart
Intensity Too High Flowchart.. .................................................................................................................
Communication Link Flowchart #l ..........................................................................................................
Communication Link Flowchart #2 ..........................................................................................................
Intensity Too Low Flowchart. ...................................................................................................................
EEPROM Write Error Flowchart .............................................................................................................
Calibration Cell in Beam Flowchart .........................................................................................................
Calibration Source Flowchart ...................................................................................................................
Calibration Cycle Aborted by Receiver
Calibration Cycle Aborted by Control Module Flowchart.. ......................................................................
Receiver in Alignment Mode Flowchart ...................................................................................................
No New Data Transmitted Flowchart. ......................................................................................................
System Reset Flowchart ............................................................................................................................
.................................................................................................................................
...........................................................................................................................
...............................................................................................
....................................................................................................
..........................................................................................................
....................................................................................................
....................................................................................
.............................................................................................
.......................................................................................
Schematic ...........................................................................
......................................................................................................
Unit Flowchart.. .........................................................................
2-10
2-12
2-14
2-15
2-16
3-10
3-13
6-10
6-14
6-16
6-18
7-18
l-19
7-20
7-21
7-22
7-23
7.24
7-25
7.26
7-27
7-28
7-29
7-30
7.31
7-32
7-33
7-34
1-l
2-2
2-3
2-4
2-5
2-6
2-7
2-8
3-1
3-2
3-2
3-3
3-3
3-5
3-7
3-8
3-9
5-2
s-4
6-2
6-4
6-6
6-7
Page 27
LIST OF ILLUSTRATIONS (Continued)
Figure
8-1.
8-2.
s-3.
s-4.
8-5.
S-6.
8-7.
8-8.
8.9.
s-10.
8-11.
8-12.
8-13.
8-14.
8-15.
8-16.
8-17.
8.18.
8-19.
X-20.
8-21.
8-22.
8-23.
8-24.
8-25.
S-26.
S-27.
X-28.
8-29.
8.30.
8-31.
8-32.
8.33.
8-34.
8-35.
8-36.
8.37.
8-38.
8.39.
8-40.
8.41.
8-42.
8-43.
s-44.
8-45.
8-46.
s-47.
S-48.
Page
Hardware Locater Source .........................................................................................................................
Intermediate Source.. ................................................................................................................................
Temperature Control Circuit Board (Stack)
Voltage Warning Cover and Insulator Board
Source Assembly ......................................................................................................................................
Source Temperature Control Wire Points.. ...............................................................................................
Temperature Control to Intermediate Source ...........................................................................................
Output to Intermediate Source.. ................................................................................................................
TB-2 Source Test Points.. .........................................................................................................................
Radiometer Back Half.. ............................................................................................................................
Radiometer Front Half.. ............................................................................................................................
Deleted
Deleted
Control Module Keyboard Detachment..
Correct vs. Incorrect Detector Installation..
Speed Sensor to Receiver .........................................................................................................................
Radiometer Rearview (Cable Clamp).
Speed Sensor Location .............................................................................................................................
Radiometer Rearview (Disassembly).
Part Locator Dual Gas Cell Subassembly..
Removal of Dual Gas Cell ........................................................................................................................
Removal Calibration Gas Cell Subassembly ............................................................................................
Radiometer Front View ............................................................................................................................
Calibration Gas Cell with Solenoid ..........................................................................................................
Rearview Radiometer for Chopper Motor Replacement ...........................................................................
Chopper Motor .........................................................................................................................................
Deleted
Chopper Motor Blade Position
Chopper Motor .........................................................................................................................................
Chopper Motor Test Set-Up .....................................................................................................................
Subassembly Locator Receiver (Reference) .............................................................................................
J4/Jl Locator ............................................................................................................................................
Deleted
Control Key Board Removal ....................................................................................................................
Control Module Circuit Locator
Voltmeter to Control Voltage Output Rear Interface Board
Control Module Output Circuit Board ......................................................................................................
Current Meter to Control Module Output .................................................................................................
Voltmeter to TP6 (Reference Voltage) Receiver
Receiver Alignment Adjustment
Infrared Source Module, Exploded View .................................................................................................
Infrrared Receiver Module, Exploded View ..............................................................................................
Infrared Receiver Module, Exploded View..
Infrared Receiver Module, Exploded View..
Control Module, Exploded View. .............................................................................................................
Gas Temperature Probe
Subassembly, Electronics Main Source Temperature Control
Subassembly, Lower Circuit Card Main Source
.....................................................................................................................................................
.................................................................................................................
...............................................................................................................
Locator .................................................................................................
............................................................................................................................
Temperature Control .............................................................................................................................
.............................................................................................
...........................................................................................
..................................................................................................
..............................................................................................
......................................................................................................
.......................................................................................................
...............................................................................................
.....................................................................
......................................................................................
............................................................................................
............................................................................................
..................................................................
8-11
S-11
8-12
8-13
8-16
8-16
8.17
8-18
8-18
8-19
8-21
8.21
8-22
8-23
8-24
8-25
8-24
8-24
8-25
8-26
8-27
8-28
8-29
8.30
8-31
8-32
8-32
8-33
8.40
8-41
8-42
8-42
8-43
8-43
s-44
8-45
8-l
8-2
8-2
8-3
8-4
8-6
8-6
s-7
8-8
Page 28
Page 29
SECTION I. GENERAL DESCRIPTION AND SPECIFICATIONS
l-l. INTRODUCTION.
The importance of controlling excess air levels in various combustion processes has
been recognized for many years. Recently however, the rising cost of fuel has made it an economic
necessity to reduce excess air levels to minimize thermal stack losses. Efforts toward combustion
efficiency optimization, however, must be aimed at reducing total energy loss. This requires achieving
minimum unburned combustibles as well as minimum thermal stack losses. More precise control of the
air/fuel ratio, optimized for minimum total energy loss, can yield significant gains in efficiency and result
in substantial savings in reduced fuel consumption.
Flue gas concentration of carbon monoxide is a reliable and accurate indication of burner flame
stoichiometry and the completeness of combustion. It is the most sensitive indicator of unburned combustibles losses. Used either as a primary combustion efficiency parameter, or in conjunction with oxygen
analysis, carbon monoxide offers significant advantages in controlling combustion at optimum levels of
excess air. Controlling air/foe1 ratio to an optimum level of carbon monoxide assures minimum total
energy loss, and maximum efficiency, independent of variations in boiler load, fuel type, and fuel quality.
The measurement is relatively unaffected by air in-leakage and burner maintenance requirements are
immediately identified.
The Model 5100 CO Analyzer sets new and superior standards of quality and reliability in providing the
many benefits of continuous flue gas carbon monoxide measurement.
1-2. DESCRIPTION.
The Rosemount Model 5100 CO Analyzer (Figure l-l) is designed to continuously
measure CO concentration levels in combustion flue gases. The analyzer consists of four main
components: an infrared source module, an infrared receiver module, a flue gas temperature probe, and
a control module. The source, temperature probe, and receiver are installed directly on the flue gas duct
or stack, eliminating the need for a costly and complex sample conditioning system. The receiver is positioned to view the source by sighting across the duct, through the flue gas to be monitored. The control
module is designed for panel mounting in the boiler control room.
2
ITEM DESCRIPTION
1
IR Source Module
2
3
4
Figure l-l. Typical Model 5100 CO Analyzer System
rE1c&mA
l-l
Page 30
The IR source is housed in a rugged, fully insulated, stainless steel and aluminum enclosure. This enclosure is
housed in a carbon steel mounting sleeve designed for welding directly to the duct. Weighing only 33 pounds
(15.0 kg), the IR source module is easily installed with a line connection to an AC power source and a
thermocouple lead back to the receiver. In normal applications no purge air is required to maintain source
cleanliness. However, in certain applications the flue gases contain constituents which can adhere to the
source and damage it through corrosion; in these applications a source purge air is required. An optional jet
pump is available. The jet pump uses pressurized, low volume plant air to induce a high volume, low pressure
ambient air purge through the purge assembly. When pressurized air is not available for the jet pump, the
Model 5100 may be equipped with an optional blower accessory. Refer to paragraph 5-3 for a description of
the source purge air assembly.
The IR receiver is housed in an epoxy-coated, cast aluminum enclosure. Like the source, the receiver is
lightweight, weighing 33 pounds (15.0 kg), facilitating installation. Contained within the receiver are the
optics and detector system, startup adjustments and signal processing electronics. The receiver incorporates an
automatic calibration system which may be activated from the control module. Signal and power connections
are made via terminal strips located in the interior of the enclosure. Should the application require purge air to
maintain clean window cleanliness, the Model 5100 is available with an optional jet pump. In negative duct
pressure applications, ambient air is naturally drawn into the jet pump, filtered, passed through the purge
assembly and into the duct. In positive duct pressure applications, pressurized, low volume plant air is
supplied to the jet pump to induce a low pressure., high volume of ambient purge air through the purge
assembly. If plant air is not available the Model 5100 may be provided with an optional air blower accessory.
The air,bIower accessory or plant ,&r must ,be provided ‘if pressure in tbe,duct is not
always a negative pressure. F&IT to do so may aIIow high i@emaI tempaatnks to
be reached in the infrared receiver causing damage to tIje equipment, or shorten its
0perationaI fifespan.
The control module provides control room access to all analyzer functions, intelligent control of all operating
functions, and complete remote diagnostic capability. The module is housed in a stainless steel enclosure, with
integral, self-attaching, panel-mount hardware. An RS-232 option is available for output to a PC.
1-3. OPERATION.
concentrations
The Model 5100 utilizes infrared absorption spectroscopy to continuously measure CO
in combustion flue gases. The IR source module is mounted directly on the flue gas duct or
stack on the side opposite the IR receiver module. Infrared energy is radiated by the source, through the flue
gas, to the receiver. The receiver employs gas filter correlation and narrow bandpass optical filtration with a
solid state detector to determine the absorption of radiation by CO in the flue gas. CO concentration levels are
computed by digital signal processing circuitry and displayed on the control module. Analog output signals of
4-20 mADC, 1-5 VDC, O-20 mADC or O-5 VDC, proportional to measured CO concentration, are generated
of input to a recording and/or combustion control system.
Page 31
1-4. PERFORMANCE SPECIFICATIONS.
Measuring Range ..................................
Continuously adjustable, O-200 to O-10,000 ppm (optical
path length dependent)’
Optical Path Length ....................................
1.5 to 40 feet (0.46 to 12.2 m); distance, source to
receiver
Flue Gas Temperature
Flue Gas Opacity ..............................................
Accuracy ...........................................................
Repeatability .....................................................
Discrimination Ratms ........................................
.......................................
200” to 600°F (93” to 316°C)
Less than 30% opacity
?20 ppm *6% of reading
+lO ppm +3% of reading
COz:CO, minimum 10,OOO:l. H,O:CO, minimum
10,000:1
Time Constant.. .................................................
Analog Output ..................................................
5 to 255 seconds, selectable from control module
4-20 mADC, O-20 mADC (600 ohms maximum load);
isolated, field selectable
Display ..............................................................
Alarms ..............................................................
Dual LCD with statlls, fault, and alarm flags
Two highnow alarms, solid state relays, 3 amp, AC, maxi-
mum rating; 170 watts resistive. One arm relay, SPDT;
780 VA inductive, 260 volts. Audible alarm (control
module). Visual alarm flags (control module).
RS-232 Output (Optional) ..________.............
Fault codeslppm CO on request if the program is initiated
by the
PC.
‘Maximum full scale operating range to which the analog output is automatically scaled is a function of
optical path length. For a given application, the product of the full scale concentration and the optical path
length may not exceed 33,ooO ppm-ft (10,000 ppm-m).
Example: Optical path length = 20 feet.
Maximum full scale operating range = 33,ooO ppm-ft. = 1,650 ppm 20 ft.
1.5. PHYSICAL SPECIFICATIONS.
Infrared Source Module
Enclosure ..........................................................
Dimensions .......................................................
Electrical Connections.. ....................................
Mounting
..........................................................
Stainless steel, carbon steel and cast aluminum
18 in. (457 mm) length; 10 in. (254 mm) diameter
Terminal strips for power and thermocouple extension
S-inch (203 mm) Schedule 5S carbon steel mounting
sleeve (Rosemount supplied)
Net Weight.. ......................................................
Ambient Temperature .......................................
33 lbs (15.0 kg)
-20” to 130°F (-29” to WC)
Page 32
Infrared Receiver Module
Enclosure.. .......................................................
Dimensions.. ...................................................
Electrical Connections.. ..............................
Distance, Receiver to
Control Module.. ...........................................
Mounting.. .......................................................
Purge Air Fitting (Jet Pump Only). .......
Net Weight.. ....................................................
Ambient Temperature.. ..............................
Control Module
Enclosure.. .......................................................
Dimensions.. ...................................................
Electrical Connections.. ..............................
Mounting.. .......................................................
Net Weight.. ....................................................
Ambient Temperature.. ..............................
lP56b’EMA 4, zinc-plated steel
12 x 12 x 16 in. (305 x 305 x 406 mm) HWD
Terminal strips for power, thermocouples and RS-422
communication
1 mile (1.61 km) maximum
To customer-supplied flange: ANSI B16.5 4-inch
(100 nun), 150 lb, flat face, weld neck flange
with four 3/4-in. bolt holes, 4 in. diameter
center hole
l/4 in. (6.35 mm) OD tube
33 lbs (15.0 kg)
-20’ to 1300F (-29” to 55OC). Temperature of the optical
system must not fall below dewpoint
EMC Rated Eurorack, rack or panel mounting
5.22 x 10.61 x 11.62 in.
(1325 x 269,5x 295 nun) (H x W x D)
Terminal strips for power, and all signals
Rack or Panel Mount
6 Ibs. (2.7 kg)
32’to 104? (0” to 40%)
Flue Gas Temuerature Probe
Enclosure.. .......................................................
Probe Dimensions.. ......................................
Electrical Connections.. ..............................
Mounting.. .......................................................
Net Weight.. ....................................................
Blower Motor
Air Flow (max). .......................................
Dimensions.. .............................................
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cast aluminum head; Inconel sensor probe.
l/4 in. (6.35 mm) dia x 36 in. (914 mm) length
Terminal strip
l/2-inch NPT
1 lbs (0.45 kg)
40cfm@10in. 0
Height 10 inches 54 nun)
Width 9.8 inches (249 nun)
Depth 11.1 inches (282 mm)
29 pounds (13,l Kg)
3
Page 33
1-6. UTILITIES SPECIFICATIONS.
Electrical Classification _........_...........
Infrared Source Module
Power
Infrared Receiver Module
Power . . . . . . . . . . . . .
Purge Air
1. Negative duct pressure-none required
2. Positive duct pressure-see Figure 2-10 for flow and pressure requirements
Control Module
Power .._.....................................
Blower Motor
Power
category Il
100.130/200-260 VAC, 50/60 Hz; 550 watts
nominal (1300 watts maximum)
100.130/200-260 VAC, 50/60 Hz; 125 watts
100.130/200-260 VAC, 50/60 Hz: 20 watts
lOO-130/200-260 VAC, 50/60 Hz, 400 watts
Page 34
Page 35
SECTION II. INSTALLATION
2-l. GENERAL.Tbis section describes the procedures required for installation of the Model 5100 CO Analyzer.
2-2. UNPACKING AND INSPECTION. Inspect the shipping container and notify the carrier immediately if any damage
is detected. Open the shipping container and inspect the individual analyzer components for damage.
SITE SELECTION AND PREPARATION. Observe the following guidelines when selecting a site for the unit.
2-3.
a. Select readily accessible positions for the IR receiver, lR source, and temperature probe on the duct or stack to allow
for routine maintenance. Periodic access to the receiver is particularly important. Comfort levels for maintenance
personnel should be a consideration in placement of the receiver unit.
b. The site should be free from excessive vibration and the ambient temperature for the source and receiver modules
must be within -20’ to 130°F (-29” to 55°C).
NOTE
To avoid condensation, the temperature of the optical system should not be allowed
to fall below the water dewpoint temperature.
c. The flue gas temperature should be in the range of 200” to 600°F (93” to 316°C).
d. The flue gas opacity should not exceed 30%.
e. The site should be downstream of any particulate removal device (e.g., electrostatic precipitator) to assure minimum
flue gas opacity.
f. The site should be upstream of any wet scrubbing device (e.g., wet flue gas desulfurization system) to assure
minimum entrained liquids in the flue gas.
g. The site should not be immediately down-stream of sharp bends in flue gas ductwork.
h. The site chosen for the receiver must be opposite a suitable site for the source
Page 36
2-4. INFRARED RECEIVER MODULE INSTALLATION.
a. Provide an ANSI B16.5 4inch (100 mm) 150 lb, flat-face weld neck llange with four 3/4 inch bolt holes, 4 inch
diameter center hole, or equivalent connection to the duct or stack. For mounting dimension refer to Figure 2-I for
IR receiver modules with jel pumps, or Figure 2-2 for IR receiver modules with hose adapters.
Damage to tbe receiver will result from hot flue gases if tbe slide window assembly
is not fidIy positioned against either of its stops.
Page 37
MXES: “NESS OMEmvlSE SPEClRED
Figure 2-2. Outline and Mounting Dimensions, Infrared Receiver Modules with Purge Air Blower Hose Adaptor
Receiver contains an internal calibration source that is heated to 1100°F (593°C);
therefore it is not suitable for installation in Class I, Division 2, areas.
Damage to the receiver will result from hot flue gases if the slide window assembly
is not fully positioned against either of its stops.
Damage to receivers mounted on positive pressure ducts will result via
transmission of hot flue gases if blower motor is not immediately turned on.
Page 38
b. Attach alignment flange (2, Figure 2-3 or 2-4) and gasket (3) to weld neck flange (4) using bolts (8),
flatwashers (5), lo&washers (6), and nuts (7).
Fit receiver to alignment flange (2) and secure with nuts (10) and lo&washers (9).
c
Complete power and signal connections. Refer to paragraph 2-8.
d.
Connect primary purge air supply, if required. Refer to paragraph 2-9
e.
8.
1. Cover
2.
Flange
3.
Gasket
4. Flange (Customer Supplied)
5. Flat Washer, 5/8 In.
6. Split Lockwasher, S/8 In.
7.
Hex Nut, 518-U
Bolt, S/8-11 x 25 In.
9. Split Lo&washer, 3/8
In.
10. Hex Nut, 3/8-16
11. Slide Window Assembly
12. Jet Pomp
13. Purge Air Filter
14. washer
15. Spool Piece (Customer Supplied)
Figure 2-3 Infrared Receiver Module Installation with Jet Pump
IBlC&SlOA
24
Page 39
1.
COWX
2.
Flange
3. Gasket
4.
Flange (Customer
Supplied)
5. Flat Washer, 5/8 In.
6. Split Lockwasher, 5/8 In.
7. Hex Nut, 518-11 In.
8. Bolt, 5/8-11x 25 In.
9. Split Lo&washer, 3/8 In.
10. Hex Nut, 3/8-16
11. Slide Window Assembly
12. Purge Air Hose Adaptor
13. Spool Piece (Customer Supplied)
Figure 2-4. Infrared Receiver Module Installation with Hose Adaptor
IElc.5-SloA
2-s
Page 40
2-5. INFRARED SOURCE MODULE INSTALLATION:
a. Cut the flanged slew to fit the duct or stack and to locate the face of the IR source flush with the in-
side surface of the duct or stack wall as shown in Figure 2-5.
o” 0
I
g$,&
0
0
0
a
0
Tl
0
0
D
O 0 O
Page 41
b.
Weld modified flanged sleeve (1, Figure 2-6) to the duct or stack.
To install the source, remove cover plate, Figure 2.6, from the sleeve and replace with so”rce module (3), “sing
e.
existing gasket (2) and eight l/4-20 bolts (4) and washers (5). (Do not racwe the four socket-head screws holding
the rear plate to the inner housing.) Save cover plate in the event that servicing the s”“rce module becomes
necessary.
d.
Complete power and signal interconnections. Refer to paragraph 2-8.
e.
Upon completion of installation, if duct insulation is to he replaced, insulate around perimeter of sleeve only. Do
not cover either temperature controller housing or rear plate of source module with insulation.
CARSON STEEL
1. Flanged Sleeve
2. Gasket
3. IR Source Module
4. Bolt, 1/4-20x 1.00 I”.
5. Split Lockwasher, l/4 In.
INLESS STEEL
Figure 2.6. Infrared Source Module Installation
The IR Source is a sealed unit containing a manmade mineral fiber know as
Fiberfrax. The material is used for insulation purposes. In the event of failure,
national and local regulations apply to the disposal of the unit.
Page 42
2-6. FLUE GAS TEMPERATURE PROBE INSTALLATION.
a. Provide a standard l/z-inch NPT coupling to the stack or duct.
NOTE
For smaller diameter ducts of less than 10 Peet (3 m), a longer coupling may be required to
locate the tip of the temperature pmbe in a more representative temperature location. This
location is appmximately 25% of the duct diameter into the duct.
b. Weld the coupling to the duct, Figure 2-7. Locate temperature probe below the plane of the IR
source and receiver. Ensure that a minimum distance of three feet (1 m) is left between the tip of tem-
perature probe and the IR source.
NOTE
Locating the temperature probe on the IR receiver side of the duct decreases thermocouple
cable run distance.
c. Install ungrounded thermocouple and interconnect to receiver. Refer to paragraph 2-8.
Figure 2-7. Flue Gas Temperature Probe Installation
IBlc!&mA
2-s
Page 43
2-7.
CONTROL MODULE INSTALLATION.
a. The control module should be located in an easily accessible area of the control room. Locate in an area free of
excessive vibration, and where the ambient temperature is within the range 32” to 104°F (0” to 40°C).
b. Provide a panel cutout of 5.25 x 9.25 in. (133 x 234 mm).
E. Insert control module into panel cutout.
d. Complete power and signal interconnections. Refer to paragraph 2-X.
2-8.
ELECTRICAL INSTALLATION.
a. In addition to AC power supply lines to the JR source, lR receiver and control modules, the following interconnect
cables are required for electrical installation:
1. Interconnect cable, infrared receiver module to control module, 3.conductor, shielded, 22 AWG. For additional
information, refer to Section 5.
2. Thermocouple wire, Type K, 24 AWG, infrared source module and flue gas temperature probe to infrared
receiver module. For additional information, refer to Section 5.
Four thm holes are located at the base of the IR receiver for cable entry. Two of these arc covered with dust caps
and two with weathertight seals. Two to four thm holes may be used, as desired, for electrical connections. Those
used should be fitted with sealed conduit fittings. Those not used should remain sealed with the weathertight seals
provided.
Three thru holes are located at the rear base of the control module. These are also covered as described above
Similar guidelines should be followed for electrical connections.
b. Observe the following during electrical installation:
1. Keep signal cables and thermocouple wires separated from power cables.
2. If signal and power cables must cross, make sure the cables cross at right angles.
3. Keep all cables away from hot objects.
NOTE
To ensure CE compliance, the outer shield of the RS422 Communications cable
should be terminated at both ends. At the Control Room Unit (CRU) a ground
point is provided on the backplane. On the IR Receiver the cable should he
terminated BEFORE entering the enclosure. A GND stud is provided.
A good Earth is essential for the proper operation of the 5100A CO Analyzer. The
chassis of the CRU, the outer casing of the IR Receiver, and the mounting plate of
the IR Source should all be connected to Earth using the GND stud connections
provided.
Page 44
t
D-
EB
PANEL CUTOUT g x 234 L PER DIN STANDARD #43700
+1 .o
Q
NOTES: UNLESS OTHERWISE SPECIFIED
Figure 2-8. Control Module Installation
9.25 +.039
-.ooo
lB-106.51OA
Z-10
Page 45
4.
Where there is a possibility of mechanical damage, be sure that the cable is armored, enclosed in
a heavy conduit, or protected in a similar fashion.
Avoid or minimize signal cable junctions. Each junction interrupts the shield and renders the
5.
output signal more susceptible to electrical noise interference.
6.
The use of a shielded transformer in the AC supply line is recommended where an instrument
supply is not available.
7.
See Figure 2-9 for electrical connections for the IR receiver, IR source, temperature probe, and
control module.
(a) Remove cover of IR source temperature controller by turning cover counterclockwise.
(b) Remove cover of IR receiver by loosening eight screws. Note that the screws are captive,
but the cover detaches completely.
(c) Connect Qpe K thermocouple wire from source to receiver.
(d) Remove screw cap of flue gas temperature probe.
(e) Connect Qpe K thermocouple wire from probe to receiver.
(f) Remove six rear cover screws and rear cover of control module.
(g) Eoyu;;t the 3-conductor, shielded communication cable from the receiver to control
(h) Connect AC power wiring to IR source through external 20 Amp circuit breaker.
(i) Connect AC power wiring to IR receiver through external 2 Amp circuit breaker.
6) Connect AC power wiring to control module through external 1 Amp circuit breaker.
8.
Additional electrical connections may be required from the control module to user-supplied
equipment. Control module rear terminal designations and descriptions follow.
ALM 1.54 Terminals 1, 2. Alarm 1 is a high/low CO concentration alarm, solid state relay,
(a)
3A, AC, maximum rating: 170 watts resistive.
ALM 2.55 Terminals 1.2. Alarm 2 is a highnow CO concentration alarm, solid state relay,
(b)
3A, AC, maximum rating 170 watts resistive.
Alarm 3, 56 Terminals 1, 2. 3. Alarm 3 is energized under a fault/error condition and in
(4
conjunction with Alarm 1 or Alarm 2. Alarm 3 is a relay, SPDT; 780 VA inductive, 260
volts.
Analog Outuut Terminals 58. J9. One of four available analog output signals proportional
Cd)
to measured CO concentration is selected using the combination of the appropriate pair of
terminals and keyboard procedures.
Current output: 4-20 mADC or O-20 mADC, 600 ohms maximum load. Use 58 terminals
l(-) and 2(+).
Voltage outputz O-5 VDC or l-5 VDC, 1000 ohms minimum load. Use J9 terminals 2(-)
and l(+).
lB-ice-SlOA
2-11
Page 46
IR SOURCE
MODULE
CONTROL MODULE
Figure 2-9. Electrical Installation
IB-106.5lOA
2-12
214mw2
Page 47
HOLD COMMAND, Terminal HO. The HOLD COMMAND places the analyzer in a
HELD OUTPUT mode of operation. To allow issuance of this command, wire a switch between terminal 1 and terminal 3 (common), paragraph 3.6.b.
HOLD FLAG, Terminal JlO. The hold flag is issued upon entering a held output mode of
operation and maintaining throughout the duration of the held output. This is a logic level
signal at terminal 2 with respect to common (terminal 3).
Logic level 1: 2.4 VDC minimum for standard TTL input.
Logic level 0: 0.6 VDC maximum at 1.6 mADC maximum sink current, paragraph 3.6.~
RS-232 Terminal ,115. Connect the RS-232 inputs to terminals 1 (IN), 2 (OUT), and 3
(COM). Install diskette lLO4438HOl into the PC and run “51OO.bat”.
2-9. PURGE AIR REOUIREMENTS.
a. M. The presence of paticulates, entrained liquids, etc., in some combustion flue gases may lead to
a coating of analyzer optical surfaces exposed to the gases. To reduce the need for periodic manual
cleaning of these surfaces (which is required to maintain proper analyzer operation), it is recommended
that the surfaces be purged continuously with clean air.
The IR source module is installed with the source surface flush with the inner wall of the duct in most
applications. Therefore, the source is subject to only minimal coating or particulate buildup, and
consequently there is no purge air requirement to maintain source cleanliness. Purge air is recommended
for the IR receiver module to maintain cleanliness of the receiver module window.
b. Negative Duct Pressure Aadications. In these applications, the IR receiver module, fitted with jet
pump as shown in Figure 2-1, is self purging. Negative duct pressure will induce ambient air flow through
the jet pump. The ambient air is filtered and passes through the purge assembly, by the window, and into
the duct. No external air supply is required if the duct pressure never goes positive.
c. Positive Duct Pressure Armlications with Jet Pumps. When the Model 5100 with optional jet pumps is
installed on a duct under positive pressure an external, primary purge air supply is required. The jet pump
is designed to accept a pressurized, low volume primary air supply to induce a low pressure, high volume
flow of filtered ambient air through the purge assembly, by the window, and into the duct.
1. Provide a primary purge air supply, either plant air or compressor. See Figure 2-10 to determine
primary supply pressure and flow requirements as functions of maximum expected duct pressure.
NOTE
The low volume primary purge air supply for the jet pump is customer supplied.
2. Using a l/4-inch (6,35 mm) tubing, connect the primary purge air supply to the jet pump through
l/4-inch tube fitting per Figure 2.1,
3. Initiate the primary purge air supply and adjust pressure to a level slightly in excess of the minimum
primary pressure determined from Figure 2.10. This will assure a positive purge flow under
conditions of nomu duct pressure and positive pressure excursions.
Page 48
9.0 M
a.5 34
a.0 32
7.5 30
FOR MAXIMUM EXPECTED DUCT PRESSUR.E,
SET PRIMARY PRESSURE AT INDICATED
VALUE OR HIGHER
EXAMPLE
DUCT PREsS”Rr 20’ Hz0 (5.0 kPd
MINIMUM PRIMARY PRESSURE: 37 psi2
f255.1 kP.1
PRIMARY AIR CONSUMPTION: 2.22 CFM
/
/
1.5 a
1.0 4
05 2
0.0 0
Figure 2-10. Purge Air Pressure and FIow Requirements for Model 5100 CO Analyzer
7
0
0.0 aa. VS.9
to
PRIMARY JEY PUMP PRESSURE, KILOPASCALS
20 30
2oa.a 275.8 244.7 412.7
Page 49
d. Positive Duct Pressure Amlications with Blower.
blowers, Figure 2-11,
provide a contimmus source of bigb volume low pressure air to the receiver
Model .5100
analyzers equipped with purge.‘air
hose adaptor, Figure 2-2.
1. Locate the air blower assembly near the module in a location that provides a source of clean
fresh purge air. 10 feet of hose is supplied with the blower. Refer to Figore 2-11, for blower
mounting dimensions.
2. Connect the blower to the module hose adaptor.
3. Connect the blower motor to ll9220 VAC power source. Run cable through the motor junction box seal fitting and connect as shown in Figure 2-12 Tighten seal fitting onto cable.
PURGE AIR
poTATl~,v
SLOWER
a.112
’ /I
I
I
Figure 2-11.
SLOT 0.41 X 0.44 LG
(4 PLACES)
VENT HOLE
I i
Outline and Mounting Dimensions, Purge Air Blower Motor
0.375 #THRU
(4 PLACES)
Page 50
GREEN
$1
WHlTE WHITE
* IN SOME APPLICATIONS THE
BLOWER MOTOR 115 VAC UNE
WHITE WIRE MAY BE BLUE, AND
THE PAACK WIRE MAY SE BROWN.
YELLOW
BROWN
BLACK
YELLOW
BLACK
MOTOR LINE’
BLUE PI
WHITE
YELLOW - 4
2%;”
ORANGE -
115 VOLT WlRlNG CONNECTIONS
115 VOLT OPERATION
GRND 2-WHlTEN
GREEN@
BLACK L
BROWN
WHlTE
MOTOR
BLUE
Ek%!
BLACK
WHITE
ORANGE -
220
VOLT WIRING CONNECTIONS
Figure 2-12. Blower Motor Wiring Connections
220 VOLT OPERATION
LINE
- mi? ,”
STND
4
WUtTE N
Page 51
SECTION Ill. OPERATIONS AND CONTROLS
3-1. THFZORY OF OPERATION. The Rosemount Model 5100 CO Analyzer operates on the principles of
infrared absorption spectroscopy. Heteroatomic molecules exhibit characteristic absorption spectra
are related to the number, configuration, and types of atoms in the molecule; the simpler the molecular
structure, the simpler the absorption spectrom. By examination of the infrared spectra of gases, it is possible to locate an infrared absorption region unique to CO or CO,
The Model 5100 is designed such that the window, lens, bandpass filter, pyroelectric detector and other
optics are toned to operate in the main absorption band of carbon monoxide. Within this band, still
higher selectivity is achieved by correlating the observed spectrum with that of a permanent sample of
carbon monoxide. The technique is termed “gas filter correlation spectroscopy”.
The infrared source is heated to approximately 11120F (600°C). This produces an in@red emission in
the region of interest, which is between 4.5 and 4.9 microns. The source is mounted on the opposite side
of the duct or stack from the receiver. Thus, the energy radiated by the source must pass through the
flue gas before being measured by the receiver. The relative percentage of radiation absorbed in the
region of interest indicates the level of CO in the flue.
Figure 3-1 shows the relative absorption of CO and CO2 in the band from 4 microns to 5 microns. Figure
3-l also shows the bandpass filter’s transmission relatwe to the absorption of CO and CO, The band
from 4.5 to 4.9 microns is selected to maxim& the response to CO. The exact shape of the filter
bandpass is chosen to mioimiz the effect of absorption due to CO, and 30 (which absorbs at%ghtly
longer wavelengths). The radiant energy in this narrow band is the only energy allowed to impinge on the
pyroclectric detector.
that
Figure 3-1. Spectral Transmittance of CO, and CO
IB-lM-SlOA
3-l
Page 52
Figure 3-2. Optical Mmmtig
Figurea3-2 and 3-3 are simpliied optical diagrams which show the critical components for determining
the infrared energy that passes through the flue gas.
The iofrared source is a large-diameter, staintess steel cyImder which is maintained at a temperatore of
approximately lll2’% (HlO”C). It is mounted opposite the IR receiver module. The receiver has a Calcium fluoride window to isolate the instrument enclosure from the tlue gas. The germanium lens focuses
the infrared energy that has not been absorbed onto the pymelectric detector.
Figure 3-3. Optical Components
Page 53
co
co
(REF CELL)
SAMP
SUMMING AMP
SOLENOID
S = AMPLITUDE OF WIDESAND INFRARED SOURCE *
A = TRANSMISSMTY OF CO IN THE FLUE AND CO
REFERENCE CELL
B = ;~;L~ISSMTY OF THE CO IN THE RUE AND
HOW
Figure 3-4. Primary Signal Processing --Analog Representation
Figure 3-4 shows the CO reference gas cell in place in the optical path. One section of the dual gas cell
assembly is filled with 100% CO atmospheric pressure and the other section is filIed with 100% nitrogen.
Both are sealed with sapphire windows. The pyroelectric detector is a charge-sensitive device which
develops a signal with changes in infrared energy. A motor-driven chopper blade is used to interrupt the
infrared beam enabling the pyroelectric detector to provide a periodic wave output at 40 Hz. An aperture is placed in front of the detector to limit the field of view to a small area on or around the infrared
source. The pyroelectric detector and its associated preamplitier produce a periodic wave signal at the
chopper frequency. The amplitude of the signal is proportional to the amplitude of the energy striking
the detector within the waveband of 4.5 to 4.9 microns, which is the bandpass of the filter.
Figure 3-5 is an analog representation used to explain how the microprocessor determines the amount of
CO in the flue. In order to explain the sequence of events, we will break it up into four steps.
4 4
9 9
Av+P.-. Av+P.-.
- R*O,OMETER - - R*O,OMETER - - LOEARlIER - - LlNEARIZER VVVVI VVVVI
vuvv% vuvv%
PAT” LEHOT” __
COYPE,‘SATlOl4
510HA.L 510HA.L
PROCESsOR PROCESsOR
VOLThOE 6
OAMP,HO - CURREnT
0”TP”T - o-aom* I 4-EOrnA
Figure 3-5. Signal Processing Block Diagram --.Analog Representation
IB-lee-510.4
3.3
GAS TEMP. GAS TEMP.
COMPrHS*TlON COMPrHS*TlON
co otsPL*v
- O-6” I l4V
Page 54
Definitions
s=
Level of infrared radiation from the source.
A= Combined transmissivity of CO in the flue gas and in the CO reference cell.
B= Combined transmissivity of CO in the flue gas and in the N, cell.
NOTE
Nitrogen does not absorb infrared energy. The lcm-atm CO relerence cell absorbs nearly
the total amount of energy that can be absorbed by CO. Therefore, the presence of CO in
the flue gas, and the associated reduction in transmissivity, will have a proportionally
greater effect upon B than upon k
a. Read the cell energy level at the detector with the CO reference cell in the optical path. Store this
reading in a sample-and-hold amplifier. We call this stored value SA.
b.
Read the energy level at the detector with the N cell in the optical path. Store this reading in a
sample-in-hold amplifier. We will call this stored v af ue SB.
c. By inverting the SA signal to get a -SA and adding it, in an inverting summing amplifier, to K(SB),
the resulting signal output is S(A-KB), which is a signal that represents the difference between
detected energy levels with and without the CO reference gas in the optical path. (The nitrogen gas
has no absorption.)
d. The signal S(A-KB) is then divided by SA in a divider circuit to obtain the signal (l-KB/A), which is
a function of the CO level in the flue gas. Notice that the amplitude of the source (S) has been cancelled out in the analysis and the output ratio is independent of the source.
The K factor is adjusted such that, when CO is not present in the flue gas, KB=A. The output of the
divider is then zero. As CO concentration in the flue gas increases, the ratio of B to A decreases; hence,
the term (I-KB/A) increases.
Figure 3-5 shows an analog representation of other adjustments and corrections made to the signal
before it is converted to an output signal.
The linearizer circuit is designed to linearize the logarithmic output of the divider. The signal is then
corrected for temperature of the flue gas and path length of the flue. The damping circuit is an adjustable filter used to reduce unwanted noise from the signal. At this point the signal is converted to a 4-20
mA, l-5 WC, O-20 mA or O-5 VDC signal that represents a zero-to-full-scale reading.
The theory of operation described above is an analog representation of the operation of the microprocessor-based receiver and control modules. Figures 3-6 and 3-7 are basic block diagrams showing the
four major components of the Model 5100 CO Analyzer. Component descriptions are given in the
following section.
3-2. DESCRIPTION OF MAJOR COMPONENTS.
a. Infrared Source Module. The source of infrared radiation ia a 4” (10 cm) diameter, stainless steel
cylinder heated by a tubular heater coil, The temperature is controlled by a solid state temperature
controller. The temperature is measured by two Type K thermocouples. One thermocouple provides
a control signal to the triac controller. The second thermocouple allows the microprocessor to
monitor source temperature, thereby indicating if the IR source is functioning properly. The temperature is nominally adjusted to 1112’F (6OO’C) for proper operation, but has a limited adjustment
range for special applications.
I&105-510.4
3-4
Page 55
1
CPU
INFRARED RECI~VER MODULF
MODULE
- -- -
INFRARED SOURCE
r
I
Page 56
b. FIue Gas Temperature Probe. The gas temperature is measured with an isolated ungrounded and
sheathed Type K thermocouple probe which is supplied with the system. Cold junction compensation is
accomplished at the receiver terminal strip.
e. Infrared Receiver Module. The receiver consist of four components. They are:
1. Purge Air/Enclosure Assembly. The purge air assembly provides a means to maintain cleanliness of the calcium fluoride window and to protect the receiver from the adverse effects of cor-
rosive flue gas constituents. Purge air requirements are described in pamgraph 2-9. The NEMA 4,
weathertight enclosure provides environmental integrity.
The calcium fluoride window is slider-mounted in the purge air/enclosure assembly. The receiver
design is such that a considerable amount of coating on the window can be tolerated. If the window
becomes excessively coated, however, this condition is detected as a fault, flagged at the control
module and cleaning is necessary. Slider mounting allows for convenient window cleaning.
Frequency of window cleaning is significantly reduced by continuous purge air.
2. Radiometer Assembly. The radiometer is a compact optical bench containing a planoconvex germanium lens, narrow bandpass optical filter, pyroelectric detector, field stop aperture, gas cells,
calibration source, motor-driven chopper blade and a photo chopper. The gas cells and calibration
source are placed into position by long-life rotary solenoids. The chopper motor speed is measured
by a photo sensor which sends feedback signals to the central processor unit (CPU).
3. Power Supply Board. The receiver power supply provides low voltage, regulated power to the CPU
hoard and radiometer as well as power for the solenoid drives. The drivers for the solenoids and the
triac driver for the calibration source are also on the power supply board.
4. CPU Board. The central processor input (CPU) consists of a Motorola 6802 microprocessor with
associated memory, peripheral interface adapter, AID converter, data multiplexer and communication device. The CPU provides timing control signals to the solenoid drivers, calibration
source and chopper motor drive circuit. It also collects data on signal levels from the pyroelectric
detector and temperature data. Formatted data is then transmitted to the control module over an
RS-422 interface.
d. Control Module. The control module is a 133 x 234 DIN size, panel-mounted enclosure with an inter-
face board, three plug-in circuit boards and the keyboard/display. The module receives digital data from
the IR receiver module and computes the correct output response. Numerous features can be programmed
from the front panel keyboard and displayed on the dual liquid crystal display (LCD). For example,
analog outputs corresponding to the computed CO concentration can be selected for O-20 mA, O-5 volts,
4-20 mA, or l-5 volts. The CPU contains electrically erasable, programmable, read-only memory
(EEPROM) to retain the system set points and operating parameters even after power outages. The CPU
continuously scans the keyboard for manual entries as well as updating the display. It also controls the
RS-422 communication interface to the IR receiver module and the optional RS-232 output to a PC.
Page 57
Figure 3-7. Control Module Block Diagram
ELlM51OA
3.1
Page 58
Figure 3-8. IR Receiver Module Controls
3-3. DESCRIITION OF CONTROLS.
a. IR Receiver Module Controls.
1. ALIGN/RUN Switch (Sl). The ALIGN/RUN switch, Figure 3-8, is placed in the ALIGN position in order to activate the LED alignment display and audible buzzer. In routine Operation,
the switch must be kept in the RUN position.
2. Intensity Adjustment Potentiometer (R18). The intensity pot, Figure 3-8, is used to adjust the
gain of the detector amplifier to the proper range for the particular installation. Proper gain will
be a function of optical path length and flue gas opacity. Clockwise rotation of this potentiometer will increase the level indicated on the LED’s.
Page 59
b. IR Souree Temoeratnre Controller Controls.
1. Temperature Setpoint Potentiometer. This pot, Figure 3-9, is set at the factory, but there may be
a need to adjust the soorce temperature during its service life. A clockwise rotation will increase
the temperature setpoint. The nominal setpoint is 1112°F (600%) and this may be increased to
1382oF (750°C).
OR 23OV 50/60 HZ
FOR 23OV UNIT ONLY
Figure 3-9. JR Source Module Temperature Contmller
e. Control Modnle. The control module, provides the central interface between the analyzer and the
operator, recording, annunciating, data acquisition and control systems The microprocessor identilies data, operating parameters, commands and other internal operations as functions. With the
exception of certain command functions, each function is assigned a two-digit function code. Access
to functions is through the keyboard. Display of data and various operational states is provided by
two liquid crystal display’s (LCD’s). The following sections describe the control module keyboard and
functions of the Model 5100 CO Analyzer.
IElM-SlOA
3.9
Page 60
r ~~~
READING
HELD OUTPUT
TEST VALUE
CO analyzer
MAN GAS T
FUNCTION
Figure 3-10. Control Module Display
1. Control Module Display-Upper Display. This is a four-digit liquid crystal display (LCD) which
indicates the reading being presented or data being entered from the keyboard. Mnemonics may
also appear in this display in selected functions (Figure 3-10).
Display Flags:
(a) Held Output. Indicates that the present ppm reading and analog output signal are being
held at either the last valid live CO value or an operator selected value (see TEST
VALUE).
The flag displays under any of the following conditions:
(1) 2nd function HOLD key is depressed.
(2) Remote HOLD COMMAND
(3) During two segments of the calibration cycle.
(4) System-disabling fault is detected by the diagnostics prqmxn:
Hue gas temperature (Diag. code #2)
3
b Radiometer temperature (Diag. code #3)
Intensity too high (Diag. code #5)
E
d Communication failure (Diag. code #6)
Intensity too low (Diag. code #7) (IfFNO6~256.)
e
is initiated.
Receiver in align mode (Diag. code #13)
f
Communication o.k., but not updating (Diag. code #14)
g
Page 61
(h) Test Value. Indicates that the present ppm reading is a manually selected value which
provides a desired analog output signal. Both reading and output signal are being held and
the held output flag is displayed simultaneously.
The flag displays only when a TEST VALUE is manually entered from the keyboard
(paragraph 3-4.a, STORE ENTRY key for keystroke sequence).
(c) PPM. Indicates that parameter displayed is expressed in units of parts-per-million,
The flag displays under any of the following conditions:
(1) Reading live, held or test CO value.
(2) Displaying full scale range.
(3) Displaying alarm setpoints and deadbands.
(d) ‘C, Meters. Indicates that temperature or optical path length presently displayed is ex-
pressed in the MKS unit system, degrees Celsius or meters, respectively.
(e) “F, Feet. Indicates that temperature or optical path length presently displayed is expressed
in the FPS unit system, degrees Farenheit or feet, respectively.
2. Control Module Display - Lower Display. This is a 3-l/2 digit liquid crystal display (LCD) which
indicates the two-digit function code corresponding to the analyzer function currently accessed.
Mnemonics may also appear in this display in selected functions.
Display Flags:
(a) CAL Cycle. Indicates either that the calibration cycle is in progress (steady flag) or that the
SET ZERO function is active (flashing flag).
The flag displays under any of the following conditions:
(1) Calibration cycle is automatically initiated by the microprocessor.
(2) Calibration is manually initiated from the keyboard by depressing the 2nd function
CALJOFF key.
(3) Primary zero calibration is initiated from the keyboard by depressing the 2nd function
SET ZERO key.
NOTE
Flag flashes under this condition.
(b) MAN Gas T. Indicates that flue gas temperature value used by the microprocessor to corn-
pute temperature-compensated CO concentration values is manually selected; the flue gas
temperature probe is not being used.
IB-1MSlOA
3.11
Page 62
(c) Fault. Indicates that microprocessor diagnostics program has detected one or more
fault/error conditions in the system The flag is accompanied by the HELD/OUTPUT flag
if the detected fault is system-disabling; and, until acknowledged or unless disabled, by:
(1) The control module audible alarm
(2) Alarm3
The flag will display until such time as the fault/error condition has been corrected (Section
7, Troubleshooting).
(d) Alarm 1. Indicates that measures CO concentration value has:
Exceeded setpoint value if alarm 1 has been programmed as a high alarm;
OR
Fallen below setpoint value if alarm 1 has been programmed as a low alarm.
The flag displays:
In conjunction with ALARM 1 triac turning on.
Until measured CO concentration value has returned to within setpoint and deadband
(paragraph 3-4.n, for explanation of deadband).
(e) Alarm 2. Indicates that measured CO concentration value has:
Exceeded setpoint value if alarm 2 has been programmed as a high alarm;
OR
Fallen below setpoint value if alarm 2 has been programmed as a low alarm.
The flag displays:
In conjunction with alarm 2 triac turning on.
Until measured CO concentration value has returned to within setpoint and deadband
(paragraph 3-4.n. for explanation of deadband).
When either alarm 1 or alarm 2 is active, alarm 3 and the audible alarm will, unless dis-
abled, be activated also and remain so until the condition is acknowledged. The alarm 1
and alarm 2 flags and triacs are not deactivated by the acknowledgment -- only alarm 3 and
the audible alarm.
(t) Disabled. Indicates that alarm 1 triac, alarm 2 triac, alarm 3 relay and control module
audible alarm are disabled.
NOTE
Hags for alarm 1, alarm 2 and fault remain operational.
The flag displays only when the 2nd function ENABLE/OFF key is depressed to toggle
from the ENABLE state to the OFF state.
IB-lC6-51OA
3.12
Page 63
3. Audible Alarm. The audible alarm is designed to provide a locally audible alert to an acknowledged
fault/error condition or a CO concentration alann (ALARM 1 or ALARM 2). The alarm buzzer is
located directly behind the keyboard/display.
(a) The audible alwm may be silenced in either of two ways:
(1) Until the next occurrence, by depressing the ACK ALARM key
(2) Permanently, by using the 2nd function ENABLE/OFF key.
(3) Reset Alarm Setpoint to higher value.
(b) The audible alarm buzzer sewes the further function of providing audible feedback of the
validity of keystroke entries:
(1) A single, short beep acknowledges a correct keystroke entry;
(2) A single, long beep indicates non-acceptance of an attempted incorrect keystroke entry.
4. Keyboard. The keyboard, Figure 3-11, provides the operator with a convenient means to access
functions and initiate commands. Depending upon the function selected, access may entail a request
to read data only; display and set or change a particular operating parameter or computational
constant: or command an action. With the exception of certain commands which may be initiated
directly from the keyboard, all functions are assigned two-digit function codes. A function may be
accessed by entering the two digits of the function code from the keyboard. A complete listing of
functions, function codes and function descriptions may be found in paragraph 3.6.
Figure 3-11. Control Module Keyboard
Page 64
To provide analyzer interface in a manner as user-friendly and convenient as possible, those timetions and commands requiring access on a routine basis are identified directly on the keyboard.
These are termed “secondary” or “2nd” functions and may be accessed directly, without the
need to enter the two-digit function code. Full descriptions of the keyboard and secondary
functions follow in paragraph 3-4.
Recognizing that access to many functions provides to opportunity to interrupt normal analyzer
operation and alter operational parameters or computational constants, thus affecting
calibration and/or analog output signal, freedom of access to such functions should be limited.
The system provides two levels of security protection for this purpose. For each level of security,
a code is required to access the protected functions. In the following function descriptions, the
terms “user locked” and “factory locked”, and the associated “usercode” and “factory code”,
refer to the two levels of security protected functions. A listing of user and factory locked functions, as well as instructions for implementing the security systems may be found in paragraphs
3-6
and 3-7.
3-4. KEYBOARD FUNCTIONS.
The following is a description of the primary and secondary functions as-
sociated with each of the 16 keys on the keyboard. Primary function of the key as printed on the lower
portion of key in bold print. Secondary function refers to the analyzer function as printed on the upper
portion of the key against the orange background. Access to a secondary function requires depressing
the 2nd KEY key, causing the mnemonic 2nd Fn to appear in the display. The desired secondary fonc-
tion key is then depressed. If the desired secondary function is one which displays data, the data appears
in the upper display and the function code appears in the lower display. Changing data in this type of
function, accessing other types of functions and fully entering user locked functions require keystroke
sequences described below. In the descriptions it is assumed that each function is being accessed on a
locked system. The step of storing the user code can be omitted if:
The user code has been set to 0.
There has been keyboard activity with no lapse of more than 5 minutes since last entering the code.
See paragraph 3-7 for a more complete description of the security system.
a. STORE ENTRY Key.
1. Primary function.
(a) Enters data into the system. Data pending storage into the system will flash in the upper dis-
play. Depressing the STORE ENTRY key will enter the data and cause it to appear steady
in the display.
(b) Initiates certain command functions.
(c) Enters test Value. The STORE ENTRY key can be used directly, whenever the system is in
its default mode (reading CO in ppm), to set the display and corresponding analog output
to a user-selected test value. This is particularly useful for calibrating a chart recorder or
any other equipment using the analog outputs. It may also be used to test ALARMS 1 and
2.
A test value, YYYY, may be entered by using the following keystroke sequence:
In-10651oA
3.14
Page 65
KEYSTROKE
DISPLAY
UPPER LOWER
FLAG
(1)
KOl
XxXx
(chrrent
co
PPM
Live ppm)
(2)
(3)
[STORE ENTRY] CODE
User
11t1t1t1
Code
USE
USE
(Flashes)
User Code
(4)
(5)
[STORE ENTRY] 0
(Flashes)
MMMM m
00
00
(Flashes)
(6)
[STORE ENTRY] YYYY
(Steady)
co
PPM
HELD OUTPUT
TEST VALUE
Additional test values can be entered by repeating Steps (4) thro (6) or, after more than 5
minutes with no keyboard activity, by repeating Steps (2) thro (6).
To leave the test value mode, use the 2nd function hold/off to remove the held/output as
described in paragraph 3-4.i
2. Secondary Function. -- None.
b. J*l Decimal PoinURESP TIME Key.
1.
Primary Function. Input decimal point into display/system. This is used in path length (FN24)
only.
2. Secondary Function, Output Filter (FN25). This function allows the user to view/adjust the time
constant of the analyzer from 0 to 255 seconds.
NOTE
This is additive to the analyzer’s inherent delay time of 5 seconds.
Example: Desired time constant = 10 seconds
Delay time = 5 seconds
Required RESP TIME entry - 5 seconds
Page 66
NOTE
Response time is the time required Par the output to change from an initial value to a
specified percentage of the final steady-state
95% is three time constants. In the example above, response time is 5 seconds (delay time)
plus 15 seconds (three time constants), or 20 seconds to reach 95% of input change.
RFSP Time is a user locked function. The current time constant, XXX, may be displayed
using the following keystroke sequence:
value
of an input change. Response time to
DISPLAY
FLAG
LOWER
25 (Function
(1)
(2)
KEYSTROKE
UPPER
[Znd KEY] 2nd Fn
t=p =I
xxx (Set)
Code)
Adjustment of the time constant requires entry of the user code and the following additional keystrokes:
(3)
(4)
[STORE ENTRY] CODE USE
[l[l[l[l
User Code
USE
(Flashes)
User Code
(5)
(‘3
(7)
[STORE ENTRY] 0 (Flashes)
MMM
YYY(Flashes) 25
[STORE ENTRY] YYY(Steady) 25
25
.Where YYY is the desired time constant io seconds.
c O/GAS TEMP Key.
1. Primruy Function. Input integer “0” into display/system.
2. Secondary Function, Gas Temperature (FNO2). This function allows the user to display the flue
gas temperature as measured by the flue gas temperature probe. (See Section 3-6 for manual gas
temperature procedures.)
The flue gas temperature, XXX may be displayed using the following keystroke sequence:
Page 67
KEYSTROKE
DISPLAY FLAG
UPPER LOWER
(1)
(2)
[2nd KEY] 2nd FII
[GAS TEMP] XXX
02
OC or OF
(Function
Code)
The displayed temperature will be that measured by the flue gas temperature probe even if
the system is using a manually set value.
d. COICE Key,
1. Primary function. Clear or exit any function and place the system in default mode (reading CO
in ppd.
NOTE
Clearing or aborting command functions which are toggled on and off, e.g. HOLD/OFF, re-
quire procedures described Par the particular functions.
2. Secondary Function, Clear Entry. This function allows the user to delete an accidental data
entry (if noticed before depressing STORE ENTRY key) within a given function. To correct an
accidental entry, depress [2nd KEY], [CE], [STORE ENTRY] and enter correct data. An
automatic CE will also occur if more than four digits are entered into the display.
e. UCALIOFF Key.
1. Primary Function. Input integer “1” into display/system.
2. Secondary Function, Calibration/Off. This function allows the user to manually initiate a calibration cycle. It also allows the user to abort either a manually or automatically initiated calibration
cycle (see paragraph 3-8, System Calibration, for detailed description and sequence of calibration cycle). CAL/OFF is a user locker function. A calibration cycle may be manually initiated
using the following keystroke sequence:
(1)
(2)
(3)
KEYSTROKE
[2nd KEY]
K~OFFI
[1[111~1
UPPER
2nd Fn
CODE USE
User Code USE
DISPLAY
LOWER
FLAG
(Flashes)
User Code
(4)
[STO= Emyl Eepnl, CO
CAL CYCLE
HELD
CO)
OUTPUT
IB-10651OA
3-17
Page 68
The calibration cycle now proceeds as described in paragraph 3-8. To abort either a
manually or automatically initiated calibration cycle, the same keystroke
is used. Upon
depressing the STORE ENTRY key, the calibration cycle is aborted. The CAL CYCLE
flag clears, but, if the output was held, it will remain held (and the HELD OUTPUT flag
displays) at current CO reading for an additional 30 seconds, after which the system
returns to the default mode, reading CO in ppm.
A manual calibration cycle cannot be initiated while a SET ZERO calibration is in
progress.
f.
2lSET ZERO Key.
1. Primary Function. Input integer “2” into displays/system.
2. Secondary function, Set Zero. This function allows the user to initiate a zero calibration cycle
using the primary IR source. The primary IR source zero factor is computed and this factor is
used to compute the system operating zero factor, and as a constant in updating the system
operating zero factor in the calibration cycle described in paragraph 3-8, System Calibration. The
zero calibration cycle will force the system to read zero ppm CO and will drive the analog signal
output to the equivalent of zero ppm CO, regardless of the actual CO concentration in the flue
gas. Therefore,
ppm flue gas CO concentration.
the zero calibration cycle should be initiated only under the condition of a zero
This condition may be created by increasing the excess air
(air/flue ratio) to a level sufficiently high to preclude the formation of CO. Often, the CO level
cannot be entirely eliminated. Therefore, the only way to assure a 0 ppm level of CO is to use a
portable combustion analyzer to measure for the presence of CO in the flue. If CO cannot be
entirely eliminated, do not proceed with second key Set Zero. In this case, function 57 can be
manually manipulated to adjust the reading of the Model 5100 CO Analyzer to agree with the
portable combustion analyzer reading at near 0 ppm CO.
NOTE
A valid zero calibration cycle cannot be performed unless the boiler is operational and gen-
erating combustion flue gases.
Refer to paragraph 3-8, System Calibration, for detailed description and sequence of the zero
calibration cycle.
SET ZERO is a user locked function. The zero calibration cycle may be initiated using the following keystroke sequence:
(1)
(2)
(3)
KEYSTROKE
[2nd KEY]
[SET ZERO]
[l[l[lrl
DISPLAY
UPPER LOWER
2nd Fn
CODE USE
User Code USE
FLAG
(Flashes)
User Code
(4)
[STORE ENTRY]
xxx
(ppm)
co
CAL CYCLE
(Flashes)
IBllE-510A
3.18
Page 69
Upon depressing the STORE ENTRY key, the zero calibration cycle begins and proceeds
as described in paragraph 3-8 for a period of two minutes, during which a live ppm CO reading is displayed. When the two-minute period has elapsed, the CAL CYCLE flag is cleared
and “Sto?” will appear in the upper display, requesting the user to accept the newly
computed zero factor. Upon depressing the STORE ENTRY key, the factor is entered, the
display reads zero ppm CO and the analog signal output goes to the equivalent of zero ppm
co.
If the user chooses not to accept the newly-computed zero factor when “Sto?” appears, the
CO key may be depressed and the system is placed in the default mode with no change.
The user can choose to abort the zero calibration cycle during the two minutes prior to the
appearance of “Sto?” by pressing the 2nd KEY and SET ZERO keys sequentially.
SET ZERO cannot be initiated while a calibration cycle is in progress.
g. 3iRANGE Key.
1. Primary Function. Input integer “3” into display/system.
2. Secondary function, Select Full Scale Range (FN21). This function allows the user to view/adjust
the full scale operating range, in ppm CO, to which the analog output is automatically scaled.
The full scale operating range is selectable from 200 to 9999 ppm. For a given application, the
maximum foil scale operating range is a timction of optical path length. The product of the full
scale concentration and the optical path length may not exceed 33,000 ppm-ft. (10,000 ppm-m).
Example:
Optical path length = 20 feet
Maximum full scale operating range = 33,000 ppm. ft.= 1,650 20 ft.
NOTE
Minimum and maximmu limits of foil scale operating range are defined to assure valid readings and analyzer performance to specitications. Although these limits are not enforced by
the analyzer software, they must be adherred to by the operator.
The analyzer can accommodate high full scale operating ranges in certain applications involving operation at elevated flue gas temperatures. Please consult Rosemount Analytical,
Inc for applications engineering assistance.
RANGE is a user locked function. The full scale operation range, XXXX, may be displayed
using the following keystroke sequence:
IElM-510A
349
Page 70
KEYSTROKE DISPLAY FLAG
UPPER LOWER
(1)
(2)
[2nd KEYI
[RANGE1
2nd
XxXx
@pm)
Fn
21
(FullCtiOll
PPM
Code).
Adjustment of the full scale operating range requires entry of the user code and the follow-
ing additional keystrokes:
(3)
(4)
[STORE ENTRY]
[ltl[l[l
CODE
User Code
USE
USE
(Flashes)
User Code
(3
[STORE ENTRY
0
21
(Flashes)
(6)
MMMM
YYYY
21
(Flashes)
(7)
[STORE ENTRY]
YYY
21
PPM
(Steady)
Where YYYY is the desired full scale range.
h. 2nd KEYiNEXT Key.
Primary Function. Allows the user to access to secondary, o12nd, functions without the need to
utilize two digit function codes. The 2nd KEY and all secondary functions are color-coded
orange on the keyboard. Depressing the 2nd KEY causes “2nd Fn” to appear in the display.
Whenever these words appear in the display, one has direct access to any of the 15 functions
shown in the upper half keys (Figure 3-9). The STORE ENTRY key is inoperative when “2nd
Fn” appears in the display.
Secondary Function, Next. This function allows the user to access functions sequentially in order
of function code, eliminating the need to enter the two-digit function codes.
E&le: To proceed from FNOl to FN02 and on to FN03, use the following keystroke
sequence:
Page 71
KEYSTROIOZ
DISPLAY FLAG
UPPER LOWER
(1)
(2) WW
(3)
(4) [NEm
[2nd KEyI 2nd Fn
YYY
02
[2nd KEY] 2nd Fn
zzz 03
Where Xxx, YYY and ZZZ are the values of the corresponding functions.
Function codes are in numeric order from 00 to 99. Functions are further structured in
smaller groups in logical order of use and these are listed in paragraph 3-6. Included in this I
listing are spare function codes not presently used. When using the NEXT function to
proceed sequentially through functions, if a spare function code is encountered, the system
returns to the default mode, FNOO (CO).
i. 4RIOLDIOFF Key.
1. Primary Function. Input integer “4” into display/system.
2. Secondary Function, Hold/Off. This function allows the user to hold the current live ppm CO
value in the display and hold the analog output signal at the corresponding value. When in the
held output mode, the toggle off function reverts the system to the default mode, live ppm
CO/output.
HOLD/OFF is a user locked function. To hold the current live ppm CO value in the display and
hold the analog output signal at the corresponding value, use the following keystroke sequence:
KEYSTROKE
DISPLAY
EL&G
UPPER LOWER
(1)
(2)
(3)
[2nd KEY]
BIOLD/OFF]
[1[1[111
2nd
CODE
User Code
Fn
USE
USE
(Flashes)
User Code
(4)
[STORE ENTRY]
Xxx (mm)
(Current
co
HELD
OUTPUT
CO)
To toggle off the HOLD/OFF function, repeat keystroke sequence (l), (2), (3), and (4).
When the STORE ENTRY key is depressed, the HELD/OUTPUT (and TEST VALUE)
flag is cleared and the system is placed in the default mode, reading CO in ppm.
Page 72
NOTE
The system wiU also be placed in the held output mode and display the held output flag
upon remote hold command when a system-disabling fault is detected by the diagnostics
program, and in 2 parts of the calibration cycle. Under these conditions, the toggle OFF
function can remove only the user requested portion of the hold. If these other conditions
are present, the output will remain held until they have been cleared. See paragraphs 3-&b,
and 7-1, for descriptions of hold command and system-disabling faults, respectively.
j. S/SAVE n Key.
1. Primary Function. Input integer “5” into display/system.
2.
Secondary Function, Save n (FN38). This function albxvs the user to store in the system
memory up to five sets of selectable system operating parameters, e.g., alarm s&points, time constant, calibration cycle frequency, etc. Parameters which are saved in each set include user
locked functions (20 through 36) and factory locked functions 53 and 57. All other functions are
common to each set.
The purpose of this function is to provide a convenient means for the user to detine and store
several sets of operating parameters corresponding to different boiler operating conditions, e.g.,
steady vs. varying load, fuel type, soot blowing, etc. For a given condition of boiler operation, the
analyzer is thus programmed for optimum operation.
NOTE
The current operating parameters are always automaticaUy kept in a power-fail protected
mode in the system’s EEPROM. The Save n feature need be used only to save additional
sets for later recall.
A set of operating parameters is identified by an integer n. Sets n = 1,2,3 and 4 are user locked.
The following instructions pertain to saving operating parameters in system memory. Refer to
paragraph 3-4.k, WRJZSTORE n Key, for instructions pertaining to the retrieval of stored sets.
To save the current set of operating parameters under the designator n = 1,2,3 or 4, use the following keystroke sequence:
Page 73
KEXSTROKJI
DISPLAY
UPPER LOWER
FLAG
(1)
(2)
[2nd KEyI
[SAVE n]
2nd Fn
n (l-5) 38 (Function
(Displays last Code
(3)
(4)
[STORE ENTRY]
t1t1t111
CODE
User Code
USE
USE
(Flashes)
User Code
(5)
(6)
[STORE ENTRY]
In1 (l-4)
0 (Flashes)
n (l-4)
(Flashes)
38
38 (Where n=
desired desig
nator for ml.-
rent save)
(7)
[STORE ENTRY
xxx @pm)
co
(Current CO)
Upon depressing [STORE ENTRY], keystroke (7), the contents of the operating registers
(i.e., the present operating parameters) are saved in the set n. Additional sets may be saved
by successive selections of operating parameters, with each set of selections followed by the
keystroke sequence (1) through (7) above, up to four sets. The operating parameters, and
the corresponding boiler operating condition, for each set should be recorded for use in
quickly restoring the proper set when necessary. Table 3-1, provides a convenient format
for recording this information.
The n = 5 set of operating parameters is factory locked. This is a precautionary measure to
assure that, regardless of parameter changes in user locked sets 1 through 4, one set of recorded parameters is maintained under a high level of security, accessible for change only
by those authorized with the factory code. To save a set of operating parameters into n = 5,
use the following keystroke sequence:
EL10641OA
3-W
Page 74
Table 3-1. System Operating Parameters/Boiler Operating Conditions Log Sheet
BOILER OPERATING CONDITIONS
PARAMETER SET n = 1 2 3
FUNCTION (FN)
RANGE (21)
ALARM 1 SETPOINT (31)
ALARM 1 DEADBAND (32)
ALARM 1 HIGH/LOW (32)
ALARM 2 SETPOINT (34)
ALARM 2 DEADBAND (35)
ALARM 2 HIGHlL.OW (36)
RESPONSE TIME (25)
AUTO CAL HOURS (20)
PROGRAM USER KEY (28)
SET GAS TEMP (27)
4 5
USER (SET ZERO) ZERO FACTOR
INITIAL SPAN FACTOR (53)
OUTPUT MODE (22)
SYSTEM UNITS (23)
PATH LENGTH (24)
INPUT FILTER (26)
CAL CELL (29)
USER CODE (30)
Page 75
KEYSTROKE
UPPER
DISPLAY
FLAG
LOWER
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
[2nd KEY]
[SAVE n]
[STORE ENTRY]
[111[1[1
User Code
[STORE ENTRY
151
[STORE ENTRY
[1[11111
User Code
[STORE ENTRY]
Bl
2nd
n (l-5)
(Last n saved
or restored
CODE
User Code.
(Flashes)
0 (Flashes)
5
(Flashes)
CODE
Factory Code
(Flashes)
0 (Flashes)
5
(Flashes)
Fll
38 (Function
Code
USE
USE
38
38
FAC
FAC
38
38
(11)
[STORE ENTRY]
Upon depressing [STORE ENTRY], keystroke (ll), the contents of the operating registers
(i.e., the present operating parameters) are saved in set n = 5.
k 6lRESTORE n Key.
Primary Function. Input integer “6” into display/system.
1.
Secondary Function, Restore n (FN39). This function allows the user to recall from system
2.
memory a set (n) of selectable system operating parameters and instantaneously input the set
into the operating registers:Please refer to paragraph 3-4.j, S/SAVE n Key, for instructions pertaining to storing sets of operating parameters.
To restore a set of operating parameters, n = 1, 2,3, 4 or 5, use the following keystroke
sequence:
xxx @pm)
(current CO)
co
Page 76
KEYSTROKE
DISPLAY
UPPER LOWER
FLAG
(1)
(2)
[2nd KEYI
[RESTORE n]
2nd Fn
n
(l-5)
(Last n saved
39 (Function
Code
or restored
(3)
(4)
[STORE ENTRY
[1[1[1[1
CODE
User Code
USE
USE
(Flashes)
User Code
(5)
(6)
[STORE ENTRY]
bl u-9
0 (Flashes)
n (l-5)
39
39
(Flashes)
(7)
[STORE ENTRY
xxx (wm)
co
(Current CO)
Upon depressing [STORE ENTRY, keystroke (7), the selected set (n) of operating
parameters is recalled from system memory and instantaneously input into the operating
registers. The selection will be rejected if the requested set has never been saved into or if
the data is otherwise unreadable. In that event, the display will stay in Fn 39 and show the
n value for the last successful save or restore in the upper display.
During routine analyzer operation under a given set n operating parameters, any or all of
these parameters may be individually changed. Although the operating registers contain the
altered parameters, the set n remains unchanged unless, or until, the altered parameters
are saved in the same set n per the procedures of paragraph 3-4.j. Accessing the SAVE n or
RESTORE n secondary functions will always cause the last n either saved or restored to
appear in the upper display.
NOTE
Initial access to the SAVE n or RESTORE
interruption/restoration will cause “0” to appear in the upper display.
n secondary functions after a power
1. USER KEY/PROGRAM Key.
1. Primary Function. Allows the user immediate access to a pre-selected function, identified by a
two-digit function code, without the need to enter the function code. Like the 2nd KEY fonction, the USER KEY function provides an added measure of convenience to the user in access-
ing a function which is expected to be accessed on a regular basis. However, unlike secondary
functions which are defined on the keyboard, the function accessed by the USER KEY function
is pre-selected by the user. Pre-selection procedures are described below under secondary
function-program.
IBlC6-SlOA
3.26
Page 77
Depressing the USER KEY key will cause the pre-selected two-digit function code to appear in
the lower display and the corresponding data to appear in the upper display.
2. Secondary Function, Program USER KEY (FN28). This function allows the user to select the
function to be accessed by the USER KEY key.
PROGRAM is a user locked function. The currently programmed function may be displayed
using the following keystroke sequence:
UEYSTROUE
(1)
(2)
[2nd KEYI
[PROGRAM] Xx
To program a new function to t
tional keystrokes:
(3)
(4)
[STORE ENTRY]
[1[11111
User Code
(3
(6)
(7)
[STORE ENTRY]
M M
[STORE ENTRY]
DISPLAY
UPPER LOWER
2nd
(FWlCtiOIl
Fn
28
FLAG
I
Code)
R accessed by the USER KEY key, use the following addi-
CODE
User Code
USE
USE
(Flashes)
0 (Flashes)
28
YY (Flashes) 28
YY (Steady) 28
m. ‘IAHAGNOSE Key.
1. Primary Function. Input integer “7” into display/system.
2. Secondary Function, Diagnostics (FNl5). This function allows the user to display diagnostic
code numbers corresponding to one or more system fault/error conditions detected by the diagnostics program.
When the FAULT flag is displayed, diagnostic code numbers may be displayed using the follow-
ing keystroke sequence:
1&106-51OA
3.27
Page 78
KEYSTROKE
DISPLAY
UPPER LOWER
FLAG
(1)
(2)
[2nd KEY]
[DIAGNOSE]
2nd
xx
(1st Diagnostic
Fn
15 (Function
Code)
Code No.
displayed for
2
seconds)
w
15
(2nd Diagnostic
Code No.
displayed for
2 seconds)
END
15
(Displayed for
2
seconds)
xx
15
(1st Diagnostic
Code No.
displayed steadily)
The display sequence indicated above is then automatically indexed, diagnostic response to a
FAULT flag generated by two system fault/errors. Should all the existing fault conditions be corrected, the FAULT tlag will automatically clear and “End” will appear io the upper display.
Multiple Paultkrrors are displayed in numeric sequence and not necessarily in order of oe
currence.
Refer to Section 7, for a more complete description of the diagnostics system, including diagnostic code numbers, associated fault/errors and diagnostics procedures.
n. S/ALARM 1
Key.
1. Primary Function. Input integer “8” into display/system.
2. Secondary Function, Alarm 1 Setpoint (FN31). This function allows the user to view/adjust the
setpoint of alarm 1 in ppm CO. The setpoint is adjustable from 0 to 9998 ppm. Entering a set-
point of 9999 ppm disables the alarm.
Alarm 1 is a user locked function. The alarm 1 setpoint may be displayed using the following
keystroke sequence:
15106410A
3.28
Page 79
KEYSTROKE DISPLAY FLAG
UPPER LOWER
(1)
(2)
Adjustment of the alarm 1 setpoint requires the following additional keystroke%
(3)
(4)
(5)
(6)
(7)
Additional alarm 1 functions are deadband (FN32) and h&b/low selection (FN33). Since the
three alarm 1 function codes are in numeric sequence, the user may proceed through them using
the NEXT function.
[2nd KEY
[ALARM l]
[STORE ENTRY
[l[l[l[l
User Code
[STORE ENTRY
MMM
(New Setpoint)
[STORE ENTRYj
2nd
xxx
(current
Setpoint)
CODE
User Code
(Flashes)
0 (Flashes)
YYY
(Flashes)
YYY
Fll
31 (Function PPM
Code
USE
USE
31
31
31 PPM
The deadband is adjustable from 0 to 9999 ppm. The deadband may be adjusted to a suitable
value to prevent repeated state changes of the alarm 1 triac as measured CO concentrations vary
about the s&point.
Example: If alarm 1 is a high alarm with a setpoiot of 500 ppm, alarm 1 turns on when the
measured CO concentration exceeds 500 ppm and turns off only when the concentration falls
below 4.50 ppm CO.
Proceeding from setpoint selection above, the deadband may be displayed/adjusted using the fol-
lowing additional keystrokes:
(8
(9) W‘=l
(10) [STORE ENTRY
[2nd KEYI
(11) MMM
(New Deadband)
(12) [STORE ENTRY]
2nd
xxx
(Current
deadband)
0 (Flashes)
YYY
(Flashes)
YYY
(Steady)
Fn
32
(Function
Code)
32
32
32
PPM
PPM
Page 80
Alarm 1 may be set as a high or low alarm. A high alarm is active whenever the ppm indicated in
FNOO exceeds the setpoint. A low alarm is active whenever the indicated ppm is equal to or less
than the setpoint. Proceeding from the keystroke sequences above, high/low selection is accomplished using the following additional keystrokes:
KEYSTROKE
DISPLAY
UPPER LOWER
(13) [2nd KEY
(14) wm
2nd Fn
0 (or 1) 33
NOTE: Displayed “0” indicates low alarm. Displayed “1” indicates high alarm.
(15) [STORE ENTRY]
(16)
tOI or 111
0 (Flashes)
0 or 1
(Flashes)
(17) [STORE ENTRY
0 or 1
(Steady)
o. 9lALARM 2 Key.
1. Primary Function. Input integer “9” into display/system.
FLAG
(Fonction
Code)
33
33
33
2. Secondary Function -- Alarm 2 Setpoint (FN34). This function allows the user to view/adjust the
setpoint of Alarm 2 in ppm CO. Display and adjustment procedures are identical to those
described in paragraph 3-4.11 for alarm 1. Function codes are 34, 35 and 36 for setpoint, dead-
band, and high/low selection, respectively. Alarm 2 may be accessed in the same manner as
described in paragraph 3-4.n for alarm 1, or the user may proceed directly from alarm 1 high/low
selection (FN33) to alarm 2 s&point (FN34) using the NEXT function.
p. ACK ALARM/ENABLE/OFF Key.
1. Primary Function, Acknowledge Alarm. Depressing the ACK ALARM key silences the audible
alarm and de-energizes the alarm 3 relay, until next occurrence. It does not torn off alarms 1,
and 2 nor does it clear display flags alarm 1, alarm 2 or fault (and held output if system-disabling
fault). Alarms 1 and 2 are turned off only when the alarm conditions are corrected or when they
are disabled through the ENABLE/OFF function described below. Display flags are cleared only
when the fault/error and alarm conditions are corrected.
The ACK ALARM key may be pressed at any time to acknowledge an alarm except when the
words “2nd Fn” appear in the display. Io this case, pressing the key will perform the secondary
function described below.
2. Secondary Function, ENABLE/OFF. This function allows the user to enable or disable the
alarm 1 triac, alarm 2 triac, alarm 3 relay and audible alarm. Display flags alarm 1, alarm 2 and
fault (and held output if system-disabling fault) remain operational in [he OFF, or disabled,
state of this function.
IB-lK-SIOA
3.30
Page 81
ENABLE/OFF is a user locked function. The user may toggle from the ENABLE to the OFF,
or disabled, state using the following keystroke sequence:
KEYSTROKE
DISPLAY
PIAG
UPPER LOWER
(1)
(2)
(3)
[2nd KEYI
[ENABLE/OFF]
[l[l[l[l
2nd Fn
CODE USE
User Code
USE
(Flashes)
User Code
(4)
[STORE ENTRY]
xxx @pm)
co
DISABLED
To toggle from the OFF state to the ENABLE state, use the same keystroke sequence (1)
through (4). Upon depressing [STORE ENTRYJ, the state change is accomplished and the DISABLED flag clears.
3-5. CO COMPUTATION. The absorption of infrared radiant energy by molecules of carbon monoxide is a
phenomenon whose characteristics are theoretically predictable. The absorption coefficient for carbon
monoxide is constant at a specific wavelength under conditions of constant temperature and pressure. If
any, or a combination, of these conditions (wavelength, temperature, pressure) changes, the absorption
coefficient changes. When applying the principles of infrared absorption spectroscopy to the measure-
ment of carbon monoxide in combustion flue gases, variations in temperature and, to a lesser extent,
pressure must be expected. The absorption characteristics of carbon monoxide, then, are also expected to
vary. Considering the dynamics of the combustion process, variations in carbon monoxide concentration
can be expected to occur simultaneously with the variations in molecular absorption characteristics. To
obtain a reliable measurement of concentration, therefore, it is necessary to compensate, or correct, the
basic measurement for errors due to temperature-induced variations in absorption characteristics.
I
Variations in flue gas temperature also cause variations in gas density. Densities of all flue gas con-
stituents vary equally and the volume concentration of carbon monoxide remains the same; however,
since the computed carbon monoxide concentration value is based upon the number of carbon monoxide
molecules encountered by the infrared radiant energy, and this number does vary with density, the gas
temperature/density fluctuations must be accounted for in the carbon monoxide computation.
The carbon monoxide computation considers finally the characteristics of the detection system, or
radiometer assembly, itself. The high degree of specificity to carbon monoxide is achieved through gas filter correlation and the narrow bandpass optical filter. The bandpass filter is placed on the pyroelectric
detector and allows the detector to respond only to a very narrow waveband of radiant energy. The width
of this band remains constant; however, its position in the spectrum varies with the ambient temperature
around the bandpass filter. To compensate for variations in absorption coefficient with spectral position,
the detector is properly characterized over the full ambient temperature range to which the analyzer will
be subjected. This characterization is incorporated into the carbon monoxide computation.
The relationship between measured carbon monoxide concentration and the factors discussed above may
be expressed as follows:
CO Oc Absorption Factor * Gas Temp Factor
Optical Path Length
lB-l(MslOA
3.31
Page 82
CO concentration values are computed by the microprocessor using the following equation:
co @pm) = 2 * FN54 * f(x) /f(y)
FN24
Where:
x=5*1-- [ FN5* * f(z) * -
213
FNOS Absorption Factor
FN04
1
y = mo2 cc, ‘73
z = FN03(%) -30
50
FN54 = System Operating Span Factor
FN24 = Optical Path Length (Meters)
FN58 = System Operating Zero Factor
FN05 = Nitrogen Cell Intensity (O-8191)
FNO4 = CO Cell Intensity (O-8191)
FN02 = Flue Gas Temperature (“C)
FN03 = Radiometer Temperature (“C)
Gas Temp Factor
296
Detector Temp Factor
@) = z. + ZIZ + zz2 + z32 + z4z4 + z52 + z,z”
2”
Where:
X, Terms are output linearizer coefficients;
Y,, Terms are gas temperature compensation coefficients;
Z,, Terms are ambient temperature coefficients for detector.
3-6. FUNCTION LISTING AND DESCRIPTION. The following is a listing and description of all analyzer
functions by two-digit function code. Any function may be accessed by entering the two-digit function
code from the keyboard. Beyond display of data in a given function, access is limited by the function
security system. This system is described in paragraph 3-7, and the level of security (user locked or factory locked) assigned each function may be found in Table 3-2.
The keystrokes required for data entry into any of these functions follow the pattern described in
paragraph 3-4. While the current value is being displayed, press STORE ENTRY. If a security code is
requested, enter that and press STORE ENTRY again. If it is a command function, the action will be
executed. If it is a data entry function, a flashing “0” will be displayed. Enter the desired data (which will
flash in the upper display pending acceptance), then press STORE ENTRY a final time. Steady display
of the desired data indicates successful entry.
IElM-510A
3.32
Page 83
FUNCTION CODE
ml
DESCRIPTION
00 (CO)
01
02
03
04
0.5
06
Default Mode -- Reading CO in ppm, subject to the filters imposed in FNZS and
FN26.
Source Temperature -- Displays the temperature of the IR source radiating surface in
degrees Celsius or Farenheit, as selected by the user in FN23. This temperature is not
updated during the held portions of the calibration cycle.
Gas Temperature -- Same as 2nd GAS TEMP function (paragraph 3-4.c.). This temperature is not updated during the held portions of the calibration cycle.
Radiometer Temperature -- Displays the temperature inside the detector tube in degrees Celsius or Farenheit, as selected by the user in FN23. This temperature is not
updated during the held portions of the calibration cycle.
Read CO Cell Intensity -- Displays the intensity (O-8191) of the infrared radiation
from the primary source as measured through the CO correlation gas cell. This signal
is filtered by the time constant in FN26. Use FNO6 during HELD OUTPUT segments
of the calibration cycle.
Read Nitrogen Cell Intensity -- Displays the intensity (O-8191) of the infrared radia-
tion from the primary source as measured through the nitrogen gas cell. This signal is
filtered by the time constant in FN26. Use FN07 during HELD OUTPUT segments
of the calibration cycle.
Read Last CO Cell Intensity -- Displays the intensity (O-8191) of the infrared radia-
tion from the primary or calibration source as last measured through the CO correla-
tion cell. FN06 may be used during held output segments of the calibration cycle, i.e.,
when the calibration soume is in the optical path.
07
08
09
10
11
12-14
Read Last Nitrogen Cell Intensity -- Displays the intensity (O-8191) of the infrared
radiation from the primary or calibration source as last measured through the
nitrogen cell. FN07 may be used during held output segments of the calibration cycle,
i.e., when the calibration source is in the optical path.
Read CO (Current Value) -- Displays currently computed ppm CO concentration
value while the output is being held at the last live ppm CO value or at a test value.
The displayed value is not filtered, i.e., the input and output filters (RN26 and 25) are
not operational during a held output mode. FN08 is not operational during the held
output segments of the calibration cycle. When the output is not held, IN08 is identi-
cal to FNOO.
Display Test -- Displays all segments and flags of both upper and lower displays.
Cold Junction Temperature -- Displays the temperature inside the receiver module
near ‘I?32 (Figure 2-7) in degrees Celsius or Farenheit, as selected by the user in
FN23. Used in computing the thermocouple temperatures displayed in F’N’s 01 and
02, and in determining FauIt/Error No’s 2 and 4. This temperature is not updated
during the held portions of the calibration cycle.
Ratio -- Displays FNO4/FNO5 x 10,000. Subject to filter imposed in FN26.
State 0 Spare -- Functions 12,13 and 14 are not currently used. Accessing any of these
functions causes the system to revert to the default mode, reading CO in ppm.
IBl%-510A
3.33
Page 84
FUNCTION CODE
m
15 Diagnostics -- Same as 2nd diagnose function (paragraph 3-4.m.).
16,17 State 0 Spare -- Functions 16 and 17 are not currently used. Accessing either of these
18 Hours -- Displays the time elapsed, in hours, since the microprocessor clock has been
DESCRIPTION
functions causes the system to revert to the default mode, reading CO in ppm.
reset. Displays 0 to 255. The clock is reset at the start of each automatic calibration
cycle, upon power interruption/restoration, or by changing value of FN20.
19
20
Minutes -- Displays the time, in minutes, of the hour displayed in FNl8.
Auto Cal Hours (O-255) -- This function allows the user to view/adjust the frequency
of the automatic calibration cycle from once per hour to once per 255 hours. An entry
of 0 prevents the automatic initiation of a calibration cycle. Any change to the stored
value resets the hours and minutes clock displayed in FN’s 18 and 19.
21
22
Select Full-Scale -- Same
as
2nd range function (paragraph 3-4.g.).
Output Mode -- This function allows the user to select which one of the four isolated
analog output signals is available at the rear terminals of the control module.
Display/Select “0”
Display/Select “1”
NOTE
Selecting “0” or “1” allows the operator to make
current outputs; but only one of
be used shnultaneously unless the
23
System Units -- This function allows the user to select the FPS unit system (degrees
these
may be used at a time. Voltage and current may not
voltage load is
greater than 20kohms.
Farenheit, feet) or the MKS unit system (degrees Celsius, meters) for:
O-20mADC or OdVDC
4-2OmADC or 1-SVDC
available the corresponding voltage and
24
25
Display of -- Source Temperature (FNOl)
Gas Temperature (FN02)
Radiometer Temperature (FNO3)
Cold Junction Temperature (FNlO)
Display/Adjustment of -- Optical Path Length (FN24)
Manual Gas Temperature (FN27)
Display/Select “0’
MKS Unit System
Display/Select “1” FPS Unit System
Path Length -- This function allows the user to set the optical path length from 1.5 to
40 feet or 0.46 to 12.2 meters. The optical path length is the distance from the IR
receiver. The path length may be set with a resolution of 0.01 foot or meter.
Output Filter (O-255 sec.) -- Same as 2nd rasp time function (paragraph 3-4.b).
(Apical value is set at 10 seconds.)
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3-34
Page 85
FUNCTION CODE
(FN)
DESCRIPTION
26
27
28
Input Filter (O-255 sec.) -- This function allows the user to impose a time constant on
the CO and nitrogen cell intensity signals prior to the computation of CO in ppm. It is
useful when reading intensities in FN04 and FRO5 and the ratio in FN’s 11 and 61.
During normal analyzer operation, this function is set to zero, unless additional filtering is required beyond the limits of the output filter.
Set Gas Tern -- This function allows the user to select automatic or manual flue gas
temperature compensation and, if manual, to select the value used by the microprocessor to compute temperature compensated CO concentration values.
Automatic temperature compensation is selected by entering a “0” into the function.
The flue gas temperature probe provides the data used by the microprocessor to compute temperature compensated CO concentration values. This is recommended for
normal operation.
Manual temperature compensation is selected by entering the expected nominal flue
gas temperature (“C or “F) into the function. Regardless of actual flue gas temperature fluctuations, the entered value will be used by the microprocessor. When manual
temperature compensation is used, the
MAN
GAS T
flag displays continuously.
Manual temperature compensation should normally be used only when the flue gas
temperature probe is out of service.
Program -- Same as 2nd program user key function (paragraph 3-4.1.).
29
Cal Cell -- This function allows the user to insert the calibration gas cell into the optical path Entry of “1” into the function will insert the cell and entry of “0” will remove
the cell from the
Data displayed during the time that the calibration cell is in the optical path must be correlated with parameters in other fonctions. FN29 is intended for specific troubleshooting pro-
cedures to be carried out by a Rosemount service representative.
During normal operation, FN29 is set to zero. Whenever FN29 is not zero, fault condition 9
will be displayed as a reminder.
30
User Code -- This function allows the user to display, change or bypass the
optical path
NOTE
user code. The analyzer is shipped from the factory with a user code of 5100.
Entry of any one, two, three or four-digit number into the function will
change the user code. Entry of “0” will bypass the user code feature. Please
refer to Section 3-7, Function Security System, for further information regarding user locked functions and the user code.
31
32
Alarm 1 Setpoint -- Same as 2nd alarm 1 function (paragraph 3-4.n).
Alarm 1 Deadband -- This function is described in paragraph 3-4.n.
33
34
Alarm 1 High/Low
Selection
-- This function is described in paragraph 3-4.n.
Alarm 2 Setpoint -- Same as 2nd alarm 2 function (paragraph 3-4.0.).
Page 86
FUNCTION CODE
aw
DESCRIPTION
35
36
37
38
39
40
41-49
Alarm 2 Deadband -- This function is described in paragraph 3-4.0.
Alarm 2 High/Low Selection -- This function is described in paragraph 3-4.0.
State 0 Spare -- Functions 37 is not currently used. Accessing this functions causes the
system to revert to the default mode, reading CO in ppm.
Save n -- Same as 2nd sake n function (paragraph 3-4.j.)
Restore n -- Same as 2nd restore n function (paragraph 3-4.k).
Truncate Negative ppm -- The Model 5100, like any other measuring instrument, is
subject to noise. If the tme reading should be 0 ppm, or a low value approaching 0
ppm, the measured ppm will vary between slightly positive and slightly negative values.
If the 4-20 mADC (l-5 VDC) option has been selected in FN22, these “negative” ppm
readings will generate an output of less then 4 mADC (or less than 1 VDC). This may
be undesirable in certain control and data acquisition systems. FN40 provides a means
to truncate the output at 0 ppm
Display/Select “0” Negative readings truncated at zero
Display/Select “1” “Live”, non-truncated zero
The mode selected applies to both FNOO and F’NO8.
State 0 Spare -- Functions 41 through 49 are not currently used. Accessing any of
these functions causes the system to revert to the default mode, reading CO in ppm.
50
51
52
53
Reference Voltage to A/D Converter (Millivolts) -- Displays the reference voltage
against which analog signals input to the A/D converter are compared for accurate
digital conversion by the IR receiver module CPU. Access for adjustment is factory
locked. (See paragraph 8-22, Reference Voltage Adjustment.)
Initial (Factory) Span Factor, Internal Calibration Source -- Displays the span factor
established at the factory using the internal calibration source and calibration gas cell.
This factor is used with the factors in functions 52 and 53 to compute the system
operating span factor (FN54). (See paragraph 3-8, System Calibration.) Access for ad-
justment is factory locked.
Calibration Cycle Span Factor, Internal Calibration Source -- Displays the span factor
established in the last manually or automatically initiated calibration cycle. The factor
is updated with each calibration cycle. This factor is used with the factors in timctions
51 and 53 to compute the system operating span factor (FN54). (See paragraph 3-8,
System Calibration.) Access for adjustment is factory locked.
Initial (Factory) Span Factor, Primary Source -- Displays the span factor established at
the factory using the primary source and an independent calibration standard. This fat.
tor is used with the factors in functions 51 and 52 to compute the system operating
span factor (FN54). (See paragraph 3-8, System Calibration.) Access for adjustment is
factory locked.
ELlC!6-51OA
3.36
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FUNCTION CODE
m
DESCRIPTION
54
5s
56
51
58
System Operating Span Factor -- Displays the span factor used by the system to compute CO in ppm (see paragraph 3-S. CO Computation). This factor is computed using
the factors in functions 51, 52 and 53 and is recomputed with each manually or
automatically initiated calibration cycle. (See paragraph 3-8, System Calibration.) Access for adjustment is factory locked.
Initial (Factory) Zero Factor, Internal Calibration Source -- Displays the zero factor
established at the factory using the internal calibration source. This factor is used with
the factors in functions 56 and 57 to compute the system operating zero factor
(FN.58). (See paragraph 3-8, System Calibration.) Access for adjustment is factory
locked.
Calibration Cycle Zero Factor, Internal Calibration Source -- Displays the zero factor
established in the last manually or automatically initiated calibration cycle. This factor
is used with the factors io functions 55 and 57 to compute the system operating zero
factor (FNS8). (See paragraph 3-8, System Calibration.) Access for adjustment is factory locked.
User (SET ZERO) Zero Factor, Primary Source -- Displays the zero factor established in the zero calibration cycle (SET ZERO) using the primary source. This factor
is used with the factors in functions 56 and 57 to compute the system operating zero
factor (FNS8). (See paragraph 3-8, System Calibration.) The value of FNS7 can be
manually selected when CO cannot be eliminated from the floe gas.
System Operating Zero Factor -- Displays the zero calibration factor used by the system to compote CO in ppm (see paragraph 3-5, CO Computation). This factor is computed using the factors in functions 55, 56 and 57 and is recomputed with each
manually or automatically initiated calibration cycle and with each zero calibration
cycle (SET ZERO). (See paragraph 3-8, System Calibration.) Access for adjustment is
factory locked.
59
60
61
62-98
99
State 0 Spare -- Function 59 is not currently used. Accessing this function causes the
system to revert to the default mode, reading CO in ppm.
Peek/Poke -- This function allows the user to access all system memory registers.
Within FN60, all memory addresses and all data contained in the registers are coded
in the hexadecimal system. Access to alter data (POKE) is factory locked. Access
should be limited to only a Rosemount service representative or the user’s designated
service personnel, carefully following the instructions contained in paragraph 3-10.
Ratio -- Displays FNO4/FNOS x 10,000. Same as FN11.
State 0 Spare -- Functions 62 through 98 are not currently used. Accessing any of
these functions causes the system to revert to the default mode, reading CO in ppm.
Re-Lock Keyboard -- This is a command function which will instantly re-lock user and
factory code-protected functions as if the normal five-minute timeout had occurred. It
can be used after data entry to insure against subsequent inadvertent changes to the
operating parameters. FN99, is, itself, not locked and, after performing its action,
automatically retmns the system to its default mode, reading CO in ppm.
IB-lO&SlOA
337
Page 88
a.
Secondarv
Functions. Analyzer functions are listed above by two-digit function code and, where applicable, corresponding secondary functions are noted with paragraph references for descriptions.
Table 3-2, also provides a convenient cross-reference. Several secondary functions (command functions) are not assigned two-digit function codes. These are:
ENABLE/OFF
HOLD/OFF
CAL/OFF
SET ZERO
NEXT
CE
All of these are folly described in paragraph 3-4.
b.
Hold Command.
The system may be placed in the held output mode and display the held output flag
upon remote hold command. The hold command is issued by a switch (user supplied) connecting terminal 28 (hold command) to terminal 30 (common) at the rear of the control module. The hold command overrides the secondary
HOLD/OFF
function, i.e., the held output mode may not be toggled
off from the keyboard.
c”
Hold Flag. Through the duration of a held output mode, regardless of the cause for entering the
mode, the system issues a logic “1” flag at terminal 29 (hold flag) at the rear of the control module.
(NOTE: Logic level “1” is a 2.4 VDC minimum for standard TTL input. Logic level “0” is a 0.6 VDC
maximum
at 1.6 mADC maximum sink current.)
3-7. FUNCTION SECURPrY SYSTEM.
Access to certain functions provides the opportunity to interropt normal analyzer operation and alter system operating parameters or computational constants. Such alterations can affect calibration, the CO computation and, ultimately, the validity of the analog output signal.
Therefore, the system is designed to limit freedom of access to such functions. The limitations are imposed by two levels of security protection. For each level of security, a code is required to access the
protected functions. Security protected functions are termed “user locked” or “factory locked” functions
and the security systems are described below.
a. User Locked Function
to
FNOO,
functions
Secur@. The user locked function security system is designed to limit access
20
through
49,
and all
keyboard
2nd functions except diagnose, next, gas temp
and CE. These user locked functions either contain system operating parameters or execute commands which interrupt normal analyzer operation. Full access to these functions can be limited, therefore, to the user(s) knowledgeable in the operation of the analyzer and authorizes with the user code.
NOTE
Data stored in a user locked function can always be displayed upon request; the function is
locked onIy in terms of altering the data.
Access to a user locked function is accomplished as follows:
1. Depress [2nd KEYJ and the desired 2nd FUNCTION key or enter the desired two-digit function code.
2. If the desired function displays data to be altered, depress [STORE ENTRY]. The system requests the user code, displaying “CODE USE”.
(a) Enter the user code, which flashes in the upper display.
Page 89
(b) Depress [STORE ENTRY]. The display flashes “O”, indicating acceptance of the user code
and requesting entry of new data into the fimction.
(c) Depress [STORE ENTRY]. The data displays steady, indicating acceptance and storage of
the data;
OR
3. If the desired function is a command function, “CODE USE” appears immediately:
(a) Enter the user code, which flashes in the upper display.
(b) Depress [STORE? ENTRY to execute the function. The lower display displays “CO” and
the upper display displays CO in ppm, either live or held, depending upon the command
function (see paragraph 3-4).
When the user code has been entered to access any user locked function, all user locked functions are
unlocked and will remain so until such time as the user has initiated no keystrokes for a continuous
period of five minutes, at which time the functions are locked once again. Storage to the user locked
functions can also be re-locked at any time by accessing FN99.
The user code is stored in function 30. The analyzer is shipped from the factory with a user code of
5100. The code may be changed by accessing FN30 as described in Paragraphs 1 and 2 above and entering the new one, two, three or four-digit user code. To bypass the user code, allowing complete
freedom of access to all user locked functions, the digit “0” is entered in FN30.
NOTE
It is strongly recommended that the user locked function security system be used. It is fur-
ther recommended that the user code be given only to those personnel knowledgeable in,
and responsible for, the proper operation of the analyzer. This will prevent inadvertent
changes in the analyzer status and operating parameters.
b. Factorv Locked Function
Securi@. The factory locked function security system is designed to limit
access to functions 50 through 60. These functions allow access to all system EEPROM registers, including the calibration factors and factory-established constants. Adjustments to data in these fnnctions are not required during normal analyzer operation. When access to these functions is required,
it should be made only by a Rosemount setvice representative or by the user% designated service per-
sonnel.
Alteration of data in functions 50 through 60 requires entry of the factory code, requested by the sys-
tem as “CODE FAC”. The factory code is “2400”.
3-8.
SYSTJSM
CALIBRATION. The analyzer requires zero calibration upon commissioning and periodically
thereafter, as described below. The zero calibration cycle establishes a zero factor using the primary
source under the condition of zero ppm in the flue gas CO concentration. Routine calibration thereafter
is performed by the analyzer’s integral automatic calibration system. A calibration cycle may be initiated
automatically by the microprocessor at a user-selected frequency or manually from the keyboard. Zero
and span corrections are made automatically. The following paragraphs describe the zero calibration
cycle and the automatic calibration cycle.
I&106-51OA
339
Page 90
a. Zero Calibration Cvcle. The zero calibration cycle causes the system to read zero ppm CO and drives
the analog output signal to the equivalent of zero ppm CO. It does this by computing a new user zero
factor (FN57), causing recomputation of the system operating zero factor (FN58) to a value which
results in an absorption factor of zero in the CO computation.
The system operating zero factor is defined as follows:
Where:
FN55 = Initial (factory) zero factor, internal calibration source
FN56 = Calibration cycle zero factor, internal calibration source
FN57 = User (SET ZERO) zero factor, primary source
FN58 = System operating zero factor
As defined previously in Section 3-5, CO @pm) is computed as follows:
Eq2CO@pln) = ,*FN54*f(x))‘f(y)
FN24
The absorption factor in the computation is f(x), where:
Eq.3x=s* I-
F!&.4f[x) = s+~x+~+~+x4x4+x+x6x6
To result io a computation of zero ppm in equation (2), corresponding to zero ppm in flue gas, the
absorption factor f(x) must be zero. From equation (4). this requires that x must be zero (X,, is
factory-set at zero).
Computing x = zero in equation (3), requires computation of the system operating zero factor as follows:
Eq.sFia = 2’3. r*FN04
Where IWO4 and FNOS are the average intensities observed during the two-minute zero calibration
and z is based on the current detector temperature.
Equation (3) becomes:
F%,.6r=S*l-
FN58 a ffif . Em5
213
L
f(z) FNo5
2’3
* f(z)
213
* f(z) * FN05 * FNO4
FNo4
1
* FNo4 * EN05
= 5 * [l - l]
=
0
Page 91
(Eq,~FM6.FN57=213. 1 e l-%04
FM5
--
f(z) FNS6
f(z) FM6 FM6
FN57, User (SET ZERO) zero factor, primary source is computed in the zero calibration cycle, and
using equation (l), FM8, the system operating zero factor is recomputed.
NOTE
During this calibration, FN55 and FN56 are held constant. FN55 is factory set. FN56 is up-
dated in the automatic calibration cycle to be discussed in the folIowing section.
The zero calibration cycle is initiated by using the 2nd set zero function as described in paragraph
3-4.f. During the two-minute duration of the cycle, CO and nitrogen cell intensity values accumulate
in system memory. When the two-minute period has elapsed, FN57 is computed and stored and
FN58 is recomputed and stored per the equations above.
Zero calibration should be performed upon initial commissioning of the analyzer and periodically
thereafter. Under continuous operation, it is recommended monthly. At times, when it is convenient
to do so, such at boiler startup, it is good practice to perform a zero calibration.
Because the zero point may vary with the quantity of interfering gases, a zero calibration should be
performed, and the User zero factor, FN57, stored in the system memory (see paragraph 3-4.j), for
each condition of boiler operation (e.g., firing a different fuel) that would significantly alter the flue
gas characteristics of carbon dioxide and water vapor content and opacity. If these conditions change
regularly, it is not necessary to perform the calibration with each change, but only to restore the ap-
propriate FNS7 (along with other system operating parameters, if applicable) from system memoxy
(see paragraph 3-4.k).
b. Automatic Calibration Cvcle.
Routine calibration is performed by the analyzer’s integral automatic
calibration system. The system employs a calibration source and calibration gas cell in the receiver
module to perform both zero and span calibrations. The calibration source acts as an alternate source
of infrared radiation to the primary source, unaffected by changes in flue gas conditions. The receiver
CPU controls the duty cycle of the calibration source heater to produce an intensity approximating
that of the primary source. When inserted into the optical path, the calibration source blocks the
radiation from the primary source, creating a CO-free optical path to the detector for zero calibration. The calibration gas cell contains 100% CO at atmospheric pressure. Since the internal path
length of the cell is 0.39 in (lcm), this represents 33,000 ppm-ft (10,000 ppm-m) of CO. When inserted into the optical path between the calibration source and the detector, this cell provides a
known concentration of CO for span calibration.
As described in the previous section, the system operating zero factor is defined as follows:
IB-lC&SlOA
3-41
Page 92
Where:
FN55 = Initial (factory factor), internal calibration source
FN56 = Calibration cycle zero factor, internal calibration source
FN57 = User (SET ZERO) zero factor, primary source
FN58 = System operating zero factor
FN56 is updated with each automatic calibration cycle. It is proportional to the (temperature compensated) CO/Nz intensity ratio observed with the internal calibration source. With FN5.5 constant and
FN57 established in the zero calibration cycle (SET ZERO). FN58, the system operating zero factor,
is recomputed with each automatic calibration cycle.
The system operating span factor is defined as follows:
Where:
FN51 = Initial (factory) span factor, internal calibration source
FN52 = Calibration cycle span factor, internal calibration source
FN53 = Initial (factory) span factor, primary source
FN54 = System operating span factor
FN52 is updated with each automatic calibration cycle. It is proportional to the output from the internal calibration gas cell. With FN’s 51 and 53 constant, FN54, the system operating span factor, is
recomputed with each automatic calibration cycle.
The automatic calibration cycle may be initiated either manually or automatically. Manual initiation
from the keyboard is accomplished using the 2nd CAUOFF function and the procedure described in
paragraph 3-4.e. The cycle is initiated automatically at the frequency selected by the user in FN20,
Auto Cal Hours (O-255), with the following exceptions:
1. If a set zero (zero calibration) is in progress at the time an automatic calibration cycle would normally begin, the start of the sequence will be deferred until the set zero has been completed.
2. If the receiver module is temporarily unable to respond (e.g., due to fault No. 6 or 13), the
calibration cycle request will remain pending until the receiver can respond.
3. If a manually initiated calibration cycle is in progress at the time an automatic
one
would nor-
mally be initiated, that manual cycle is taken fulhhiig the calibration requirement.
IB-lO&SlOA
3-n
Page 93
NOTE
It is recommended that the system be programmed for calibration every 24 hours.
c. The following is a description of the sequence of events of the calibration cycle, beginning at time O:OO,
initiation of the cycle.
NOTE
Automatic initiation of the calibration cycle or changing FN20, Auto Cal Hours, resets
the microprocessor clock to 0:OO. Manual initiation does not reset the clock.
1. At time 0~00 minutes.
(a) The CAL cycle flag displays and will continue to display throughout the calibration cycle.
(b) The held output flag displays. The output is held at the last live CO value.
(c) The hold flag appears across terminals JlO-2 and JlO-3 on the control module’s rezu terminal
board.
(d) A solenoid positions the unheated calibration source in the optical path. This provides a dark
value to the detector and stores it in memory for computing the zero point of CO and nitrogen
cell intensities.
2. At time 1:15 minutes. The calibration source is moved out of the optical path and begins to heat up
at a predetermined duty cycle.
3. At time 1:45 minutes.
(a) The held output flag clears and the analyzer returns to reading live CO.
(b) The hold flag is removed.
4. At time 7: 15 minutes.
(a) The heated calibration source is positioned in the optical path.
(b) The held output flag displays. The output is held at the last live CO value.
(c) The hold flag appears aaoss terminals JlO-2 and HO-3 on the control module’s rear terminal
board.
(d) CO and nitrogen cell intensity values accumulate in the system memory. The values are
compared to the intensity from the primary source.
Page 94
NOTE
If values differ significantly, the calibration cycle reverts to step 2 with a higher or lower
duty cycle, as appropriate.
The values are averaged and a ratio is computed. This ratio is used to compute FN56, calibra-
tion cycle zero factor. The new FN56 is
inserted
in equation (1) to recompute FN58, system
operating zero factor, to the value which results in an absorption factor of zero in the CO com-
putation. FN’s 56 and 58 are stored in system memory.
5. At time 8:30* minutes.
(a) A solenoid positions the calibration gas sell in the optical path.
(b) CO and nitrogen cell intensity values accumulate in system memory. Values are averaged and a
ratio is computed. This ratio is used to compute FN52, calibration cycle span factor. The new
FN.52 is inserted in equation (9) to recompute J?N54, system operating span factor, to a value
which results in a correctly calibrated span. FN’s 52 and 54 are stored in system memory.
6. At time 9:45* minutes.
(a) The calibration source is turned off and is removed from the optical path.
@) The calibration gas cell is removed from the optical path.
7. At time 10:15* minutes,
(a) The held output flag clears and the analyzer returns to reading live CO.
(b) The hold flag is removed.
(c) The CAL cycle flag clears.
* In the event of the condition cited in the note in Step 4.(d), these times may be delayed by up to
five six-minute increments. This is only likely to occur if power has been removed from the IR
receiver module since its last automatic calibration cycle.
Page 95
Page 96
Page 97
3-9. PEEK AND POKE SYSTEM MEMORY. To (peek) is to look at data in a memory address. To (poke)
is to change data in a memory address.
From time to time it may be necessary to access system memory,
i.e., detector replacement, control module CPU circuit board replacement. To accomplish this requires
familiarity with the following information.
NOTE
When accessing the peek and poke function (FN60) great care must be taken during ad-
dress selection, data acquisition and data modification. Improper address selection and
data modification may result in improper system operation thus requiring system
reprogramming. If this occurs contact the factory (see back cover of this manual for the factory phone number) with the control module and detector serial numbers.
a. The Hexadecimal Number System.
The hexadecimal number system is based on the number 16,
whereas the decimal number system is based on the number 10. The example below is intended to
show what is meant by the numbers that both systems are based upon.
EXAMPLE
Decimal number 15,049 is made up of five digits located in five separate positions. The locations are
[l] the 10,000 position, [S] the 1,000 position, [0] the 100 position, [4] the 10 position and [9] the 1
position. The decimal number can be written as follows:
(lx10,000) + (5x1,000) + (0x100) + (4x10) +(9x1) = 15,049
(10,000) + (5,000) + (0) + (40) + (9) = 15,049
As you can see, the decimal number system is based on the number 10 or the multiple of fhe number
10, as seen in the first example. (10,000) (1,000) (100) (10) (1).
For speed and convenience we will state the position values exponentially as seen below for the
decimal system.
10,000 = lo4 10 = 10’
1,000 = lo3 1=1oo
100 = 102
!
I
15,049 = (lxlti) + (5xld) + (0x102) + (4x10’) + (9xlOO)
15,049 = 10,000 + 5,000 + 0 + 40 + 9
Now that we have a basic understanding of the decimal system, let us look at the hexadecimal system.
The hexadecimal system is based on the number 16. This means that unlike the decimal systems, posi-
tion being valued by multiples of the number 10, the hexadecimal system values it’s positions with the
number 16.
IB-106SlOA
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EXAMPLE:
Hexadecimal number 3AC9 has four positions:
[31 PI [Cl [91
We will state the position value exponentially:
131
(3~16~)
163 = 4.096
(3~4,096)
r91
(9x16’)
16’=1
W)
As in the decimal system, there are individual position factors (single digits) that give specific value to
each position. In the hexadecimal system, they are as follows:
o=o 5=5
A= 10
F=15
1=1 6=6 B=ll
2=2
3=3 8=8
I=1
c-12
D = 13
4=4 9=9 E=14
With this understanding, we can translate the example number 3AC9 as follows:
[31
(3~16~)
(3~4,096)
WI
@x162)
(~55)
[Cl
(C~16~)
(QW
[91
(9x16’)
(9a
(3~4,096) (10x256) (12x16)
(12,288)
ww
(192)
15,049 = 12,288 + 2,560 + 192 + 9
b. The Hexadecimal System Used by the 5100. Hexadecimal (BASE 16) notation is used to convert bi-
nary (BASE 2) numbers into a usable format for operators. Binary numbers are what computers use
for all data transfer within the memory. The numbers can become very long, thus extremely tedious
to enter using a keyboard. Hexadecimal numbers are used because they can be converted directly into
binary numbers by the computer using a very short program and little memory. To read the contents
of memory, or to store in memory new data values, it may be necessary to convert decimal (BASE 10)
numbers into hexadecimal, and visa versa.
I
Table 3-3. Example Conversion
DECIMAL HEXADECIMAL
1 1
2 2
3 3
4 4
5 5
6 6
I I
8 8
9 9
10 a
I
1B106510A
34
DECIMAL HEXADECIMAL
11
B
12 C
13 D
14 E
15 F
16 10
17 11
25 19
26
1A
I
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For very large numbers it is necessary to follow the conversion example listed below:
Converting Hexadecimal To Decimal
Example: Example:
3~16~ = 3~16~ = 3 x 4096 = 3 x 4096 =
12288 12288
Ax16’= 10x 256= 2560 Ax16’= 10x 256= 2560
cX16l= cX16l= 12x 16 = 12x 16 =
192 192
9x16’= 9x 1= 9 9x16’= 9x 1= 9
Hexadecimal Decimal
3AC9= 15,049
CONVERTING DECIMAL TO HEXADECIMAL
15049,, =
940
16 15049
144
64
64
9
Least Significant Digit
58
16 940
80
140
128
12
Second Least Significant Digit -
(12 =c )
3
16 58
48
10
Third Least Significant Digit
-I
(12 = A )
0
16
Most Significant Digit
3
3-10. HOW TO CHANGE ADDRESSES IN FUNCTION 60 @zek&Poke).
a. Press [6][0] displayed in LCD should be an address in the lower display and data in the upper display.
Example: 4000 Upper Display
E2E Lower Display
b. Press decimal point key [.] display will change to four blinking zeros in upper display. The notation
ADR (address) will be shown in the lower display.
Example: 0000 Upper Display
Adr
Lower Display
lFSX!&51OA
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Many codes for addresses will be in both numbers and letters. Number values range from 0 to 9. The
c.
letters range is A, B, C, D, E, F; EE2E for example:
1. To enter a number, simply press the corresponding number key on the keyboard.
Example: Entering the number 4.
2. To enter a letter press the number [0], then, press the user key one time for every letter, F
through A.
Example: Entering address. We will choose EE2E for the example.
(a) Press [O], then press the user key two times. You should then see: “OOOE” in the upper dis-
play.
NOTE
Numbers and letters can be scrolled through in the forward or reverse directions by pressing the decimal point or user keys respectively. To move the desired number or letter to the
left one place, thus readying the control module for the next number or letter entry, a ownher key must be pressed.
Press [O]; press the user key two times. You should then see: “OOEE” in the upper display.
(b)
Press [2]. You will see: “OEE2” in the upper display.
w
Press [O]; press the user key two times. You should see the following display: “EE2E” in
((0
the upper display.
Press [STORE ENTRY]. You will see the following display: 4000 upper display.
(e)
E2E lower display
This code is EE2E, however, the lower display will show only 3-l/2 digits.
3-11. HOW TO ENTER DATA INTO AN ADDRESS IN FUNCTION 60 week & Poke).
a. Call up the address you wish to start with (see paragraph 3-10.a).
b. Follow paragraph 3-10 to obtain the addresses in the lower display and the data in that address dis-
played in the upper display.
Example: 4000 Upper Display
E2E Lower Display
c Press [STORE ENTRY] key.
d. If a factory code is asked for, go to 3-1l.e. If not, proceed to 3-1l.f.
e. Enter factory code [2][4][0][0]. Press [STORE ENTRY.
f. You should see zero (0000) flashing in the upper display and the address in the lower display.
IB-lC!6-510A
3.50
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