Rosemount 7D Thermal Conductivity Analyzer Explosion Proof-Rev M Manuals & Guides

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Instruction Manual

748221-M July 2002

Model 7D

Thermal Conductivity Analyzer

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Emerson Process Management

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

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

• If you do not understand any of the instructions, contact your Rosemount Analytical representative

for clarification.

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

• Inform and educate your personnel in the proper installation, operation, and maintenance of

the product.

• Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes. Connect all products to the

proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts specified by Rosemount. Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.

The information contained in this document is subject to change without notice. Teflon is a registered trademark of E.I. duPont de Nemours and Co., Inc.

SNOOP is a registered trademark of NUPRO Co.

Rosemount Analytical Inc. Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com

http://www.processanalytic.com

Model 7D

PREFACE................................................................................................................................ P-1

Definitions................................................................................................................................ P-1

Intended Use Statement ............................................................................................................P-2

Safety Summary....................................................................................................................... P-2

General Precautions For Handling And Storing High Pressure Gas Cylinders............................... P-4

Documentation .........................................................................................................................P-5

Compliances ............................................................................................................................ P-5

1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1

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

1-2 Analyzer Module ...........................................................................................................1-1

1-3 Gas Selector Panel .......................................................................................................1-4

1-4 Specifications............................................................................................................... 1-5

Instruction Manual

748221-M

July 2002

TABLE OF CONTENTS

a. Thermal Conductivity Cell........................................................................................ 1-1

b. Electronic Circuitry ..................................................................................................1-3

2-0 INSTALLATION ...........................................................................................................2-1

2-1 Facility Preparation....................................................................................................... 2-1

a. Installation Drawings............................................................................................... 2-1

b. Customer Electrical Connections ............................................................................. 2-1

c. Flow Diagrams ....................................................................................................... 2-1

d. Location and Mounting ............................................................................................ 2-1

2-2 Unpacking.................................................................................................................... 2-1

2-3 Gas Requirements........................................................................................................ 2-1

a. General.................................................................................................................. 2-1

b. Calibration Gas Requirements .................................................................................2-1

c. Sample Gas Composition ........................................................................................2-1

d. Suppressed-Zero Ranges ....................................................................................... 2-2

2-4 Leak Check ..................................................................................................................2-3

2-5 Gas Connections.......................................................................................................... 2-3

2-6 Recorder Output Selection and Cable Connections .........................................................2-7

a. Standard (Non-linearized) Voltage Output ................................................................ 2-7

b. Linearized Voltage Output (Optional)....................................................................... 2-7

c. Isolated 4 to 20 mA Current Output (Optional) .......................................................... 2-7

d. Dual Alarms (Optional) ............................................................................................2-9

e. Linearized Voltage, Two Ranges (Optional) ..............................................................2-10

f. Linearized Voltage and Isolated 4 to 20 mA Current Output (Optional) ....................... 2-11

2-7 Electrical Power Connections ........................................................................................ 2-12

3-0 STARTUP AND OPERATION....................................................................................... 3-1

3-1 Analyzer Controls and Adjustments ............................................................................... 3-1

3-2 Gas Selector Panel Controls ......................................................................................... 3-1

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

3-4 Calibration.................................................................................................................... 3-2

3-5 Routine Operation......................................................................................................... 3-2

3-6 Recommended Calibration Frequency ........................................................................... 3-3

3-7 Shutdown..................................................................................................................... 3-3

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

Instruction Manual

748221-M July 2002

4-0 THEORY...................................................................................................................... 4-1

4-1 Thermal Conductivity Cell and Associated Bridge Adj ustments........................................4-1

4-2 Electronic Circuitry ........................................................................................................4-1

a. Master Board.......................................................................................................... 4-1

b. Voltage Output Linearizer Board (Optional).............................................................. 4-2

c. Isolated 4 to 20 mA Current Output Board (Optional)................................................. 4-4

d. Bridge Power Supply .............................................................................................. 4-4

e. ±15 Volt Power Supply ............................................................................................4-4

f. Detector Blocks...................................................................................................... 4-4

g. Case Temperature Controller Assembly ...................................................................4-5

h. Dual Alarms (Option).............................................................................................. 4-5

5-0 SERVICE AND MAINTENANCE ................................................................................... 5-1

5-1 Thermal Conductivity Cell.............................................................................................. 5-1

5-2 Electronic Circuitry ........................................................................................................5-1

a. Amplifier Zero Adjustments ..................................................................................... 5-1

b. Bridge Balance and Range Sensitivity Adjustments .................................................. 5-2

c. Bridge Voltage Adjustment ...................................................................................... 5-2

d. Case Temperature Cont roller..................................................................................5-3

e. Dual Alarm Module (Optional).................................................................................. 5-3

5-3 Suppressed Zero Adjustment ........................................................................................ 5-3

Model 7D

6-0 REPLACEMENT PARTS ..............................................................................................6-1

6-1 Circuit Board Replacement Policy.................................................................................. 6-1

6-2 Replacement Parts....................................................................................................... 6-1

a. Selected Replacement Parts................................................................................... 6-2

b. Temperature Control Assembly ............................................................................... 6-2

c. Alarm Option ..........................................................................................................6-2

d. Range Switch Kit ....................................................................................................6-2

6-3 Matrix .......................................................................................................................... 6-3

7-0 RETURN OF MATERIAL.............................................................................................. 7-1

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

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

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

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

Model 7D

Figure 1-1. Model 7D Front Panel Controls........................................................................ 1-2

Figure 1-2. Model 7D – Location of Major Components...................................................... 1-3

Figure 1-3. Typical Gas Selector Panel ............................................................................. 1-4

Figure 2-1. Gas Selector Panel for Thermal Conductivity Cell with Sealed-In Reference Figure 2-2. Gas Selector Panel for Thermal Conductivity Cell Using Flowing Reference

Figure 2-3. Connection of Analyzer Using Sealed-In Reference Gas to Associated Gas ....... 2-4

Figure 2-4. Connection of Analyzer Using Flowing Reference Gas to Associated Gas

Figure 2-5. Electrical Connections ..................................................................................... 2-6

Figure 2-6. Master Board.................................................................................................. 2-8

Figure 2-7. Alarm Adjustments ......................................................................................... 2-9

Figure 2-8. Typical Alarm Settings .................................................................................. 2-11

Figure 2-9. Case Heater Temperature Control Board ....................................................... 2-12

Figure 4-1. Thermal Conductivity Cell................................................................................ 4-3

Figure 6-1. Analyzer Assembly - Door and Pneumatic Components .................................... 6-4

Figure 6-2. Analyzer Assembly - Electronic Components.................................................... 6-5

Figure 6-3. Temperature Control Assembly ....................................................................... 6-6

Instruction Manual

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July 2002

LIST OF ILLUSTRATIONS

Gas ............................................................................................................... 2-2

Gas ............................................................................................................... 2-3

Selector Panel ................................................................................................ 2-5

LIST OF TABLES

Table 1-1. Available Gas Selector Panels......................................................................... 1-4

Table 2-1. Alarm Output Connections .............................................................................. 2-9

Table 4-1. Range Switch Connections .............................................................................. 4-2

LIST OF DRAWINGS

613561 Schematic Diagram, Bridge Power Supply - Regulated 5 to 15V 619710 Schematic Diagram, 15V Power Supply 624003 Schematic Diagram, Temperature Controller 652813 Schematic Diagram, Isolated Current Output 652863 Schematic Diagram, Linearizer Board 654616 Schematic Diagram, Master Board 654625 Installation Drawing, Model 7D 654642 Wiring Diagram, Model 7D

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

Instruction Manual

748221-M July 2002

Model 7D

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

Instruction Manual

Model 7D

PREFACE

The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the Model 7D.

Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.

DEFINITIONS

The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout this publication.

DANGER .

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July 2002

Highlights the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.

WARNING .

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of perso nnel.

CAUTION.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure, condition or statement.

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1

Instruction Manual

748221-M July 2002

Model 7D

INTENDED USE STATEMENT

The Model 7D is intended for use as an industrial process measurement device only. It is not intended for use in medical, diagnostic, or life support applications, and no independent agency certifications or approvals are to be implied as covering such application.

SAFETY SUMMARY

If this equipment is used in a manner not specified in these instructions, protective systems may be impaired.

AUTHORIZED PERSONNEL

To avoid explosion, loss of life, personal injury and damage to this equipment and on-site property, all personnel authorized to install, operate and service the this equipment should be thoroughly familiar with and strictly follow the instructions in this manual. SAVE THESE INSTRUCTIONS.

DANGER.

ELECTRICAL SHOCK HAZARD

Do not operate without doors and covers secure. Servicing requires access to live parts which can cause death or serious injury. Refer servicing to qualified pe rsonnel.

For safety and proper performance this instrument must be connected to a properly grounded three-wire source of power.

Before supplying electrical power to the analyzer, remove power to the bridge by disconnecting the red lead from the bridge to TB1-1 or TB1-2 (depending on the bridge polarity). See drawing 654642. To safeguard against filament damage, this lead should remain disconnected until proper gas flow has been established.

WARNING.

ELECTRICAL SHOCK HAZARD

Do not operate the Model 7D Explosion-Proof Analyzer without the lens cover and door in place with all bolts secured, unless location have been determined to be non-hazardous.

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

Instruction Manual

Model 7D

WARNING.

POSSIBLE EXPLOSION HAZARD

Ensure that all gas connections are made as labeled and are leak free. Improper gas connections could result in explosion or death.

WARNING .

POSSIBLE EXPLOSION HAZARD

This analyzer is of a type capable of analysis of sample gases which may be flammable. If used for analysis of such gases, the instruments explosion-proof encl osure must be suitable for the gas.

If explosive gases are introduced into this analyzer, the sample containment system must be carefully leak-checked upon installation and before initial startup, during routine maintenance and any time the integrity of the sample containment system is broken, to ensure the system is in leak-proof condition. Leak-check instructions are provided in Section 2-4 on page 2-3.

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July 2002

Internal leaks resulting from failure to observe these precautions could result in an explosion causing death, personal injury or property damage.

CAUTION .

PRESSURIZED GAS

This analyzer requires periodic calibration with known zero and standard gases. See General Precautions for Ha ndling and Storing High Pressure Gas Cylinders, page P-4

CAUTION

PARTS INTEGRITY

Tampering or unauthorized substitution of components may adversely affect safety of this product. Use only factory documented components for repair.

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

Instruction Manual

748221-M July 2002

Model 7D

GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH

PRESSURE GAS CYL INDERS

Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed Gases" published in 1981

Compressed Gas Association 1235 Jefferson Davis Highway Arlington, Virginia 22202

Used by Permission

1. Never drop cylinders or permit them to strike each other violently.

2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when located in areas where extreme temper atures are prevalent.

3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or placed in a cylinder stand, and is ready to be used.

4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a suitable hand-truck.

5. Never tamper with safety devices in valves or cylinders.

6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is attached to a pressurized system.

7. No part of cylinder should be subjected to a temperature higher than 125°F (52°C). A flame should never be permitted to come in contact with any part of a compressed gas cylinder.

8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, precautions must be taken to prevent striking an arc against the cylinder.

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

Instruction Manual

Model 7D

DOCUMENTATION

The following Model 7D instruction materials are available. Contact Customer Service Center or the local representative to order.

748221 Instruction Manual (this document)

COMPLIANCES

The explosion-proof Model 7D is approved by Factory Mutual Research Corp. (FMRC) for installation in Class I, Groups B, C, and D, Division 1 hazardous locations as defined in the National Electrical Code (NEC), ANSI/NFPA-70.

748221-M

July 2002

APPROVED

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

Instruction Manual

748221-M July 2002

Model 7D

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

Model 7D

Instruction Manual

748221-M

July 2002

SECTION 1

DESCRIPTION AND SPECIFICATIONS

1-1 OVERVIEW

The Model 7D Thermal Conductivity Analyzer is designed to continuously measure the concentration of a single component of interest in a flowing gas mixture. The measurement is based on the different thermal conductivity's of the individual components of the sample stream. The method is especially well suited to analysis of two-component sample streams. However, analysis of multi-component streams is possible if the various components of the background gas occur in relatively constant ratio, or have similar thermal conducti vity's.

Each Model 7D Analyzer is factory -assembled, as ordered, for determination of a specified component, with specified range of concentration, contained in a background component or background mixture of known composition. Typical examples include: 0 to 100 % hydrogen in nitrogen; 20 to 50 % helium in methane; and 0% to 3% carbon dioxide in air. If so ordered, the instrument is provided with two or three ranges; selectable via a front -panel switch. Information specific to the individual instrument is provided in the Data Sheet in the rear of this manual inserted in the back of this instruction manual.

A Model 7D Analyzer consists of an analyzer module, Section 1-2 below, and, if ordered, an accessory gas selector panel, Section 1-3 on page 1-4.

1-2 ANALYZER MODULE

The analyzer module is supplied in an explosion-proof enclosure suitable for installation in hazardous locations classified as Class I, Division 1, Groups B, C, and D per the National Electrical Code (ANSI/NFPA 70) (See DWG 654625).

a. Thermal Conductivity Cell

sample and reference gases. In all applications, the sample passage receives a continuous flow of sample gas. Depending on the application, the reference passage may receive a continuous flow of reference gas, or may have the reference gas sealed within.

The sample passage contains a pair of temperature-sensitive resistive filaments. The reference passage contains a similar pair. Electrically, the filaments are connected as legs of a Wheatstone bridge. An internal voltage-regulated power supply is connected via a 20-ohm dropping resistor, to the bridge.

With the power supply output adjusted to provide an appropriate voltage across the bridge, an electric current flows through the filaments, heating them and thus increasing their electrical resistance. The heat -dissipation rate for each filament depends on the thermal conductivity of the surrounding gas.

Initially, with suitable downscale calibration gas flowing through the sample passage (and also through the reference passage if of the flow-through configuration), the bridge is balanced. Thereafter, any change in the relative proportions of the components passing through the sample passage changes the thermal conductivity of the gas mixture, causing a temperature differential between sample and reference filaments. The resultant change in filament resistance unbalances the bridge, applying a signal to the electronic circuitry (Section 1-2b on page 1-3).

The thermal conductivity cell is a metal block with separate passages for the

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

Instruction Manual

Model 7D

748221-M July 2002

ALARM 1 ALARM 2

50%

0% 100%

Rosemount Analytical

Model 7D

ZERO SPAN

RANGE

75%25%

1 3

50%

0% 100%

Model 7D

Thermal Conductivity

Analyzer

75%25%

ZERO SPAN

ALARM 1 ALARM 2

25%

50%

75%

RANGE

1 3

0% 100%

Rosemount Analytical

Figure 1-1. Model 7D Front Panel Controls

50%

25%

0% 100%

Thermal Conductivity

75%

Analyzer

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

Model 7D

Alarm Kit

15V Power Supply

Linearizer Board

Isolated Current Output Board

Bridge Power Supply

Temperature Control Assembly

Master Board

AC Power Input

Instruction Manual

748221-M

July 2002

b. Electronic Circuitry

The analyzer module contains solid-state circuitry that conditions the bridge-imbalance signal as required to provide readout on the front -panel meter. In addition, a field-selectable output for a voltage-type recorder is provided as standard. A field-selectable output of 4 to 20 mA for a current -actuated recorder or other device is obtainable through use of an optional plug-in circuit bo ard. A calibration curve can be used to convert meter or recorder readings into

concentration values. Typical calibration curves are supplied for standard ranges. Calibration curves for special ranges are available as options.

To avoid use of a calibration curve in an application where it would otherwise be required, the analyzer may be equipped with an optional linearizer board. If so, the linearizer is factory set for a given range only, and is not usable on another range. Note that a linearizer is usable only if nonlinearity at midscale does not exceed approximately 20% of fullscale.

REF Hinge Side

Fuse

Cell Enclosure

Terminal Block TB6

Figure 1-2. Model 7D – Location of Major Components

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

Instruction Manual

CAL GAS

1 Reference Gas

Sample/Calibration

Downscale

Upscale

Sample Gas

1 Reference Gas

748221-M July 2002

Model 7D

1-3 GAS SELECTOR PANEL

If so ordered, the analyzer module is provided with an appropriate gas selector panel, Figure 1-3 below. The gas selector panel permits selection, flow adjustment, and flow measurement for the various gases: sample; flowing reference gas, if used; and downscale and upscale calibration gases. Proper choice of a gas selector panel depends on:

Flow Meter

Calibration Gas Needle Valve

DOWNSCALE

1. Configuration of the thermal conductivity cell, i.e., flowing or sealed-in reference gas.

2. Composition of the sample stream. For non-corrosive streams, the gas selector panel is assembled with brass components. For corrosive streams, stainless steel is used.

Gas Flow Meter

SAMPLE

Needle Valve

Calibration Gas Needle Valve

UPSCALE

CAL GAS

REF

SAMPLE

REFERENCE

Needle Valve

1 Provided only if thermal conductivity cell uses flowing reference gas.

Figure 1-3. Typical Gas Selector Panel

DESCRIPTION PART NUM BER

Brass and Copper construction for use with sealed reference 113357 Stainless steel construction for use with sealed reference 113920 Brass and Copper construction for use with flowing reference 117195 Stainless steel construction for use with flowing reference 118210

Table 1-1. Available Gas Selector Panels

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

Model 7D

1-4 SPECIFICATIONS

Reproducibility ............................. ±0.5% of fullscale

Zero Drift1................................... ±1% of fullscale per 24 hours

Span Drift1................................... ±1% of fullscale per 24 hours

Noise.......................................... Less than ±0.5% of fullscale

Cell Response Time2................... 30 seconds for 95% response, with sample flow of 250 cc/min.

Sample Flow................................ Nominal, 50 to 350 cc/min; recommended, 250 cc/min.

Calibration Gas Flow.................... Nominal, 50 to 350 cc/min; recommended, 250 cc/min.

Reference Gas Flow (If Req’d) ...... 5 to 50 cc/min.

Supply Pressure.......................... 10 to 50 psig (69 to 345 kPa)

Meter .......................................... Indicating analog meter is standard.

Operating Ranges ........................ Various zero-based and zero-suppressed ranges, from 0% to

Ambient Temperature Range ........ 32°F to 100°F (0 °C to 38°C). Case Temperature controlled at

Output Voltage

Standard Non-Linearized....... Switch selectable: 0 to 10 mV, 0 to 100 mV, 0 to 1V or 0 to 5V DC

Optional Linearized ............... Switch selectable: 0 to 10 mV, 0 to 100 mV, 0 to 1V or 0 to 5V DC

Isolated Current Output (Option) ... 4 to 20 mA, maximum load 1500 ohms

Dual Alarms (Option).................... Relay contact rating: 1.0 A, 120V AC; 5.0 A, 120V DC, resistive

Cell Materials (Standard Cell) ....... 316 stainless steel block with tungsten or Hitempco filaments.

Power Requirements.................... 115/230 VAC ±10%, 50/60 Hz, 250 Watts

Enclosure.................................... Class I, Groups B, C and D, Division 1 hazardous locations

Instruction Manual

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July 2002

100%, are available. Single range is standard; switch-selectable dual or triple range is optional.

117°F (47°C).

loads

Corrosion-resistant filaments available on order

(ANSI/NFPA 70)

Zero and Span drift specifications based on ambient temperature shifts of less than 18 Fahrenheit degrees (10 Celsius de-

grees) at a maximum rate of 18 Fahrenheit degrees (11 Celsius degrees) per hour.

Cell response time is less than 45 seconds for 95% response, with sample flow rate of 250 cc/min, for the following gas

combinations: Argon and air, nitrogen, or oxygen; carbon dioxide and argon, nitrogen, or oxygen; helium and methane; hydrogen and methane.

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

Instruction Manual

748221-M July 2002

Model 7D

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

Model 7D

Instruction Manual

748221-M

July 2002

SECTION 2

INSTALLATION

2-1 FACILITY PREPARATION

Sections 2-1a through 2-1d provide information that may be required prior to installation.

a. Installation Drawings

For outline and mounting dimensions of the analyzer and gas selector panel modules, refer to drawing 654625 and Figure 2-1 on page 2-2 or Figure 2-2 on page 2-3.

b. Customer Electrical Connections

Customer electrical connections are shown in Figure 2-5 on page 2-6.

c. Flow Diagrams

For gas connections, refer to appropriate flow diagram:

• Analyzer using sealed reference gas,

Figure 2-3 on page 2-4

• Analyzer using flowing reference gas,

Figure 2-4 on page 2-5.

d. Location and Mounting

Location

Proper location for the analyzer depends on two basic considerations:

• Accessibility to the sampling point

• Protection of the instrument

Ideally, the analyzer should be located as close to the sampling point as possible. Short sample lines reduce time lag in readings. In practice, however, protection of the instrument sometimes calls for more remote placement.

The analyzer should be mounted in a clean, dry atmosphere. Ambient temperature should be within the range of 32oF to 100 F (0oC to 38oC).

Mounting

The analyzer is designed for surface mounting, utilizing the hardware provided. Refer to drawing 654625.

2-2 UNPACKING

The Model 7D Thermal Conductivity Analyzer is a precision instrument and should be handled carefully. Carefully examine the shipping carton and contents for signs of damage. Immediately notify the carrier if the carton or its contents are damaged. Retain the carton and packing material until the instrument is operational.

2-3 GAS REQUIREMENTS

a. General

The Model 7D requires cylinder gases appropriate to the particular application (refer to the Data Sheet inserted in the rear of this manual). Suitable gases are available from various suppliers.

b. Calibration Gas Requirements

For calibration, the analyzer requires a downscale and an upscale calibration gas, both normally specified in the Data Sheet in the rear of this manual. Proper choice of calibration gases for a particular application depends on the composition of the sample stream and the operating range used.

c. Sample Gas Composition

In a typical application, the sample gas consists of two components, for example: hydrogen in nitrogen. In this example,

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1

Instruction Manual

10.25

8.25

Mounting Holes (4)

748221-M July 2002

Model 7D

hydrogen is designated the “measured component” and nitrogen constitutes the “background gas.”

d. Suppressed-Zero Ranges

With any zero-suppressed range, the

zero-concentration point for the measured component lies offscale, below the lower range-limit. A typical example is 80% to 100% hydrogen in nitrogen. Here the appropriate upscale calibration gas would be pure hydrogen. The downscale gas would have a composition appropriate to establishing a calibration point slightly above the lower range-limit e.g., 81% hydrogen in nitrogen.

WARNING

POSSIBLE EXPLOSION HAZARD

This analyzer is of a type capable of analysis of sample gases which may be flammable. If used for analysis of such gases, the instruments explosion-proof enclosure must be suitable for the gas.

Internal leaks resulting from failure to observe these precautions could result in an explosion causing death, personal injury or property damage.

Span Gas In

To Analyzer Zero Gas In

Sample In

[210]

NO. 8 Flat Head Screw

[260]

ZERO SPAN

SAMPLE

Figure 2-1. Gas Selector Panel for Thermal Conductivity Cell with Sealed-In Reference Gas

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

Model 7D

Upscale

To Analyzer

Downscale

1.25

To Analyzer

3.25

.12

Mounting Holes (4)

10.25

8.25

Instruction Manual

748221-M

July 2002

Sample Gas

Sample Inlet

Ref Gas

Ref Gas Inlet

Calibration Gas

[83]

[3]

[32]

[210]

NO. 8 Flat Head Screw

DOWNSCALE

CALIBRATION GAS

UPSCALE

CALIBRATION GAS

[260]

REF SAMPLE

Figure 2-2. Gas Selector Panel for Thermal Conductivity Cell Using Flowing Re ference Gas

SAMPLE

REF

2-4 LEAK CHECK

Pressurize the system with air or inert gas such as nitrogen, making sure not to exceed specified pressure limitation.

Liberally cover all fittings, seals and other possible sources of leakage with leak test liquid such as SNOOP (PN 837801).

Bubbling or foaming indicates leakage, which MUST be corrected before introduction of flammable-sample and/or application of electrical power.

2-5 GAS CONNECTIONS

The analyzer and gas selector panel modules must be interconnected according to the flow diagram specified in the Data Sheet at the rear of this manual. Gas fittings on both modules are tagged as to use. Fittings are 1/4-inch NPT for 1/4-inch (6.3 mm) tubing. For interconnection, use 1/4-inch (6.3 mm) copper or stainless steel tubing, depending on whether the sample stream is corrosive.

Refer to Figure 2-3 on page 2-4, or Figure 2-4 on page 2-5 and drawing 654625. Connect sample/calibration gas lines to fittings tagged “INLET” on bottom of analyzer. Connect appropriate vent line to fitting labeled “OUTLET.”

Follow similar procedure for reference gas, if any.

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

Instruction Manual

Sample In

Needle

Flowmeter

To Vent

Thermal Conductivity Cell

Reference Gas

748221-M July 2002

Model 7D

Sealed-In

Zero Standard Gas

Span Standard Gas

Valves

113357 or 113920

Gas Selector Panel

Thermal Conductivity Analyzer

Figure 2-3. Connection of Analyzer Using Sealed-In Reference Gas to Associated Gas

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

Model 7D

Upscale

Sample Gas

Model 7D

Thermal Conductivity Cell

117195 or 118210

Reference

Needle

Sample

Downscale

Gas

Upscale

Sample Gas

Reference

Model 7D

Thermal Conductivity Cell

117195 or 118210

Downscale

Used as

Needle

Sample

A. DIFFERENT REFERENCE GAS AND CALIBRATION GAS

Instruction Manual

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July 2002

Gas

Downscale Calibration Gas

Calibration Gas

Valves

Gas Selector Panel

Reference

Gas

Flowmeter

Gas

Flowmeter

B. REFERENCE GAS ALSO USED AS CALIBRATION GAS

Thermal Conductivity

Analyzer

Sample

Vent

Reference

Vent

Calibration Gas

Calibration

Calibration Gas

Valves

Gas Selector Panel

Gas

Flowmeter

Gas

Flowmeter

Thermal Conductivity

Analyzer

Sample

Vent

Reference

Vent

Figure 2-4. Connection of Analyzer Using Flowing Reference Gas to Associated Gas Selector Panel

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

Instruction Manual

862209

748221-M July 2002

OPTIONAL DUAL ALARMS

13 14 15 17 19

TB10

16 18

DETECTOR ASSEMBLY

Model 7D

Heater

7 5 4 3 1

TEMPERATURE CONTROL

ASSEMBLY

Fan

RECORDER VOLTAGE OUTPUT AND CURRENT OUTPUT

TB4

(-) CURRENT

(+) CURRENT

(-) VOLTAGE

(+) VOLTAGE

AC POWER INPUT

Fuse

TB6

1 2 3

L1 L2 GND

DC POWER SUPPLIES

Figure 2-5. Electrical Connections

MASTER BOARD

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

Model 7D

Instruction Manual

748221-M

July 2002

CAUTION

Do not plug or restrict vents.

2-6 RECORDER OUTPUT SELECTION AND CA-

BLE CONNECTIONS

If a recorder, controller, or other output device is used, connect it to the analyzer (refer to drawing 654642) via a number 22 or number 24 AWG two-conductor shielded cable. Route the cable through conduit to the analyzer, and into the case through the appropriate opening shown in drawing 654625.

NOTE

Route recorder cable through a separate conduit, not with power cable.

Output selection and cable connections for voltage-actuated and current -actuated devices are explained in Sections 2-6a below through 2-6e on page 2-10.

a. Standard (Non-linearized) Voltage

Output

1. On the Master Board (Figure 2-6 on page 2-8):

a. Verify that TB2-1 is jumpered to

TB2-2.

b. Set S1 for desired voltage: 5V,

1V, .1V, or .01V.

b. Linearized Voltage Output (Optional)

1. Verify that Voltage-Output Linearizer Board (PN 633756) is properly inserted in J102.

2. On the Master Board (Figure 2-6 on page 2-8):

a. Verify that TB2-1 is jumpered to

TB2-4, and TB2-2 is jumped to TB2-5.

b. Set S1 for desired voltage: 5V,

1V, .1 V, or .01 V.

c. Connect the recorder cable to

the TB4 terminals labeled VOLT OUT: TB4-1 (+) and TB4-2 (-).

NOTE

Take the usual precautions to avoid AC pickup. DO NOT GROUND EITHER LEAD.

3. Connect the cable to the recorder input terminals; ensure that polarity is correct.

c. Isolated 4 to 20 mA Current Output

(Optional)

1. Verify that the Isolated 4 to 20 mA Current Output Board (PN 652816) is properly inserted in J103.

c. Connect the recorder cable to

the TB4 terminals labeled VOLT OUT: TB4-1(+) and TB4-2(-).

NOTE

Take the usual precautions to avoid AC pickup. DO NOT GROUND EITHER LEAD.

2. Connect the cable to input terminals of the recorder; ensure that polarity is correct.

3. Ground shield on one end only.

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

2. On the Master Board (Figure 2-6 on page 2-8):

a. Verify that TB2-1 is jumpered to

TB2-2 and TB2-2 is jumpered to TB2-6.

b. Connect the recorder cable to

the TB4 terminals labeled CUR OUT: TB4-3 (+) and TB4-4 (-).

3. Connect the cable to the recorder input terminals; ensure that polarity is correct. Total resistance of the output device and associated cable must not exceed 1500 ohms.

Instruction Manual

FAN

115V 230V

TB2

6 5 4

3 2 1

BOARD

J101

J100

J103

J102

TB3

TB5

TP1

TP2

TB1

6 5 4

3 2 1

OUT

HEATER

R12

R11

R15

AR1

R27R1R5C3C1

R3R2C5C6R23

AR3C7 R19

R21 R18

R17

R20J7J211

748221-M July 2002

Model 7D

POWER

CUR

- + - +

VOLT

R4 R9 R7 R22 R26 R6 R8

TB4

F13

R10

R14

AR2

R24

R16

OPTIONS

RESISTOR SELECT

RANGE

SPAN

METER

1 2 3 4

1 2 3 4 5 6 7 8

1 1

TP3 TP4 TP5

DETECTOR

R100

S1 Used to select voltage output range: 5V, 1V, 0.1V, or .01V

AR1 gain adjust. Permits adjustment of AR1 gain from X1 to

X100, to establish the sensitivity desired for Range 1. This is the highest sensitivity range.

AR1 zero adjust. Used to eliminate voltage offset within AR1 and Bridge, and provide zero suppression.

Setting determines attenuation factor applicable to AR2 output, Range 3.

Setting determines attenuation factor applicable to AR2 output Range 2.

Permits adjusting meter fullscale to agree with recorder fullscale

.01V .1V 1V 5V

DETAIL OF S1

R6, R8, R26

R22 R15 Used to eliminate voltage offset within AR2.

R16

Sets the stable ±10 V source.

Figure 2-6. Master Board

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

Model 7D

Deadband Potentiometer

OUTPUT

Instruction Manual

748221-M

July 2002

d. Dual Alarms (Optional)

The alarm module is installed in the instrument as shown in Figure 1-2 on page 1-3 and electrical connections are shown in drawing 654642. The analyzer is factory configured and requires no user adjustments.

Pins for AC power (1, 2, and 3), alarm setpoint control (8, 10, 18, and 19), and signal from analyzer circuitry (7 and 9) are wired at the factory. Connections of the remaining pins depend on individual application requirements.

If the instrument has this option, the analyzer will have the following setpoint adjustment potentiometers: Alarm 1 (the Low Alarm) and Alarm 2 (the High Alarm) on the front panel

FRONT VIEW OF ALARM MODULE

( Figure 1-1 on page 1-2) and Deadband on the alarm module (see Figure 2-7 below).

The power and input signals have been wired to the terminal strip into which the alarm module plugs. The wiring to the contacts (18 or 20 AWG) is routed through a conduit hole (see Drawing

654625).

The alarm relay is in energized mode when power is applied. Wire output to the appropriate contact (see Figure 2-5 on page 2-6 and Table 2-1 below). The Form C relay contacts are rated at 5 A, 120 VDC and 1 A, 120 VAC, resistive loads.

A lit LED next to the Deadband pots indicates the alarm is activated.

ALARM 1 LED Indicator

ALARM 1

ALARM 2 LED Indicator

ALARM 2

Deadband

ZERO

SPAN

Figure 2-7. Alarm Adjustments

11 N.C. #1 14 N.O. #2 12 COM #1 15 COM #2 13 N.O. #1 16 N.C. #2

Contact Rating: 1.0 A, 120 VAC; 5.0 A, 120 VAC. Form C, resistive loads.

Table 2-1. Alarm Output Connections

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

Instruction Manual

748221-M July 2002

Model 7D

NOTE:

The Zero and Span for setting the input voltage from the analyzer has been set at the factory. To check it, see Section 5-2e on page 5-3.

The following is recommended:

1. A fuse should be inserted into the line between the customer-supplied power supply and the alarm module terminals on the Alarm Relay Assembly.

2. If the alarm contacts are connected to any device that produces radio frequency interference (RFI), the device should be arc -suppressed (P/N 858728 Arc Suppressor is recommended).

3. The analyzer and any RFI-producing device should operate on different AC power sources to avoid RFI.

Removal of AC power from the analyzer, as in a power failure, de-energizes both alarm module relays, setting an alarm condition. Switching characteristics of the ALARM 1 and ALARM 2 relays are as follows:

corresponds to setpoint minus deadband (see Figure 2-8 on page 2-11 ).

Fail-safe Applications

By making the appropriate connections to the double-throw relay contacts, the operator can obtain either 1) a contact closure or contact opening for an energized relay, or 2) a contact closure or contact opening for a de-energized relay. For fail-safe applications, the operator must understand which circuit conditions are required to achieve relay de-energization in the event of power failure.

e. Linearized Voltage, Two Ranges

(Optional)

1. Verify that the Voltage Output Linearizer Board (PN 633756) is properly inserted in both J102 and J103.

2. Verify that the range switch on the door is properly connected: Position (Range) 1 to TB2-5, Position 2 to TB2-3, Wiper to TB2-2.

3. On the Master Board (Figure 2-6 on page 2-8):

Alarm 1 Relay

The ALARM 1 relay coil is de-energized when the meter needle moves downscale through the value that corresponds to setpoint minus deadband. This relay coil is energized when the needle moves upscale through the value that corresponds to setpoint plus deadband (see Figure 2-8 on page 2-11 ).

Alarm 2 Relay

The ALARM 2 relay coil is de-energized when the meter needle moves upscale through the value that corresponds to the setpoint plus deadband. This relay coil is energized when the needle moves downscale through the value that

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

Take the usual precautions to avoid AC pickup. DO NOT GROUND EITHER LEAD.

a. Verify that TB2-1 is jumpered to

TB2-4, and TB2-4 is jumped to

TB2-6. b. Select desired range on S1. c. Connect recorder cable to the

TB4 terminals labeled VOLT

OUT: TB4-1 (+) and TB4-2 (-).

NOTE

4. Connect the cable to the recorder input terminals; ensure that polarity is correct.

Model 7D

4030205550

A. Typical ALARM 1 Setting (LOW)

DEADBAND SET FOR

20% OF FULLSCALE

B. Typical ALARM 2 Setting (HIGH)

DEADBAND SET FOR

10% OF FULLSCALE

INPUT SIGNAL

Percent of Fullscale

INPUT SIGNAL

Percent of Fullscale

Instruction Manual

748221-M

July 2002

When input signal moves upscale through this point, the coil of ALARM 1 relay (K1) is energized, providing continuity between the common and normally-closed contacts of the relay.

ALARM 1 Setpoint

When input signal moves downscale through this point, the coil of ALARM 1 relay (K1) is de-energized, providing continuity between the common and normally-open contacts of the relay.

When input signal moves upscale through this point, the coil of ALARM 2 relay (K2) is de-energized, providing continuity between the common and normally-open contacts of the relay.

ALARM 2 Setpoint

When input signal moves upscale through this point, the coil of ALARM 2 relay (K2) is energized, providing continuity between the common and normally-closed contacts of the relay.

Figure 2-8. Typical Alarm Settings

f. Linearized Voltage and Isolated 4 to 20

mA Current Output (Optional)

1. Verify that the Voltage Output Linearizer Board (PN 633756) is properly inserted in J102.

2. Verify that the Isolated 4 to 20 mA Current Output Board (PN 652816) is properly inserted in J103.

3. On the Master Board (Figure 2-6 on page 2-8):

a. Verify that TB2-1 is jumped to

TB2-4, TB2-2 is jumped to TB2-5, and TB2-5 is jumped to TB2-6.

b. Set S1 for the desired voltage: 5

V, 1 V, .1 V, or .01 V.

c. Connect the recorder cable to

the TB4 terminals labeled VOLT OUT: TB4-1 (+) and TB4-2 (-).

NOTE

Take the usual precautions to avoid AC pickup. DO NOT GROUND EITHER LEAD.

4. Connect the cable to recorder VOLTAGE input terminals; ensure that polarity is correct.

5. On the Master Board (Figure 2-6 on page 2-8):

a. Connect the recorder cable to

the TB4 terminals labeled CUR OUT: TB4-3 (+) and TB4-4 (-).

b. Connect the cable to the

recorder CURRENT input terminals; ensure that polarity is correct.

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

Instruction Manual

SENSOR

TEST

HEATER

J17

115

TEMP CONTROL BD

115

748221-M July 2002

Model 7D

2-7 ELECTRICAL POWER CONNECTIONS

WARNING

ELECTRICAL SHOCK HAZARD

For safety and proper performance, this instrument must be connected to a properly grounded three-wire source of power.

Before supplying electrical power to analyzer, disconnect the red lead from the bridge to TB1-1 or TB1-2 (depending on bridge polarity). This action disconnects power to the bridge (see drawing 654642). To safeguard against filament damage, this lead should remain disconnected until proper gas flow has been established.

The analyzer is supplied, as ordered, for operation on 107 to 127 or 214 to 254 VAC, 50/60 Hz, 250 watts. Verify that the power source conforms to the requirements of the individual instrument as noted on the name rating plate. Ensure that switches S2 on the Master Board (Figure 2-6 on page 2-8) and S3 on the case heater temperature control board (see Figure 2-9 below) are set to required voltage.

Electrical power is supplied to the analyzer via a customer-supplied three-conductor cable, type SJT, minimum wire size 18 AWG. Route the power cable through conduit and into the appropriate opening in the instrument case (see drawing 654625). On TB6, Figure 2-5 on page 2-6, connect cable leads to terminals 1 (HOT/L1), 2 (NEUT/L2), and 3 (GND).

Set switch window for voltage required

400A 880 951E

C2R10 R11 R7 R8

CR1

R17R16 R12 CR

J18

AR1

R13

R2R1

POWER SUPPLY

R9 R5

J19

J11

R15 R14

POWER LINE J5

C4 3 2 1

1 2 1 2 3

T.I.F.

Figure 2-9. Case Heater Temperature Control Board

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

Model 7D

Instruction Manual

748221-M

July 2002

SECTION 3

STARTUP AND OPERATION

3-1 ANALYZER CONTROLS AND ADJUS T-

MENTS

Normal operation of the analyzer involves adjustments of only the front-panel controls: ZERO and SPAN, and RANGE Switch, if provided. See Figure 1-1 on page 1-2.

The various internal adjustments are factory set and normally do not require readjustment except after replacement of a circuit board or major component. Refer to Section 5, Service and Maintenance

3-2 GAS SELECTOR PANEL CONTROLS

The controls provided on the optional gas selector panel will depend on the application. For use of sealed-in reference gas, refer to Figure 2-1 on page 2-2 and Figure 2-3 on page 2-4. For flowing reference gas, refer to Figure 2-2 on page 2-3 and Figure 2-4 on page 2-5.

3-3 STARTUP PROCEDURE

WARNING

POSSIBLE EXPLOSION HAZARD

If explosive gases are introduced into this analyzer, the sample containment system must be carefully leak-checked upon installation and before initial startup, during routine maintenance and any time the integrity of the sample containment system is broken, to ensure the system is in leakproof condition. Leak-check instructions are provided in Section 2-4 on page 2-3.

Internal leaks resulting from failure to observe these precautions could result in an explosion causing death, personal injury or property damage.

WARNING

FILAMENT DAMAGE

Never apply power to analyzer without gas flowing. The filaments in the cell tend to deteriorate faster than normal.

NOTE:

Before supplying electrical power to the analyzer, disconnect the red lead from the bridge to TB1-1 or TB1-2 on the Master Board (depending on detector bridge polarity). This action disconnects power to the bridge. To safeguard against filament damage, this lead should remain disco nnected until proper gas flow has been es tablished. Refer to drawing 654642.

After performing a leak check, start up the analyzer as follows:

1. Remove the connector from J2 on the Master Board (Figure 2-6 on page 2-8). Verify that this line goes to TB6, located at the lower left of the instrument (see Figure 1-2 on page 1-3 ). If it does not, make corrections using drawing 654642 as a reference.

2. Set regulators on the gas cylinders for a supply pressure of 10 to 50 psig f(69 to 345 kPa).

3. Provide a sample flow of 50 to 350 cc/minute through the analyzer. A rate of 250 cc/minute is recommended unless faster flow is desired to reduce sample transport time.

4. If the thermal conductivity cell uses flowing reference gas, provide a reference flow of 5 to 50 cc/minute.

Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-1

Instruction Manual

748221-M July 2002

Model 7D

5. Refer to drawing 654642 and Figure 2-6 on page 2-8. Connect the cable from TB6 to J2 on the Master Board to provide AC power to the Master Board. Reconnect the red lead of TB1 (or TB2) to provide power to the detector. Apply power to the analyzer. The filaments will now begin to heat. Verify proper flow of sample gas and flowing reference gas, if used.

6. Allow the analyzer to warm-up for a minimum of six hours to ensure temperature equilibrium.

NOTE:

If ambient temperature is below 60°F (15.6°C), or if the temperature will go below 60°F (15.6°C) within the next six hours, al-

low a minimum of 12 hours for the instrument to stabilize.

Startup is now complete; the analyzer is ready for calibration per Section 3-4 below.

3-4 CALIBRATION

1. Set downscale calibration point as follows:

a. On the analyzer, set front-panel

SPAN control to midscale (five turns). If the analyzer has front-panel RANGE Switch, set it at Range 1, the highest sensitivity range.

b. Admit downscale calibration gas to

the analyzer at the same flow rate as is used for sample gas. Wait for the reading on the meter or recorder to stabilize.

c. On the analyzer, adjust the front

panel ZERO control so that the reading on the front panel meter or recorder is appropriate to the downscale calibration gas.

2. Set upscale calibration point as follows: a. If the analyzer has a front panel

RANGE switch, set it for the desired range.

b. Admit upscale calibration gas to the

analyzer at the same flow rate as is used for sample gas. Wait for the reading on the meter or recorder to stabilize.

c. On the analyzer, adjust the front

panel SPAN control so that the reading on the front panel meter or recorder is appropriate to the upscale calibration gas.

If a proper reading is unobtainable by adjustment of the SPAN control, refer to Section 5, Service and Maintenance.

After the downscale and upscale calibration points have been established, the analyzer is ready for routine operation per Section 3-5 below.

If the analyzer has Suppressed-Zero Ranges and does not calibrate properly, refer to Section 5-3 on page 5-3 for Suppressed Zero Adjustment.

3-5 ROUTINE OPERATION

First, complete startup per Section 3. If the analyzer has more than one range, turn front panel RANGE Switch to desired position. Admit sample gas at the previously selected flow rate. The analyzer will continuously indicate the concentration of the measured component in the sample stream.

A calibration curve can be used to convert meter or recorder readings to concentration values. Typical calibration curves are supplied for standard ranges. Calibration curves for special ranges are available as options.

d. If a proper reading is unobtainable by

adjustment of the ZERO control, refer to Section 5-2b on page 5-2.

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

To avoid use of a calibration curve in an application where it would otherwise be required, the analyzer may be equipped with an optional linearizer board. If so, the

Model 7D

linearizer board is factory set for a given range only, and is not usable on another range. Note that a linearizer is usable only if nonlinearity at midscale does not exceed 20% of fullscale.

3-6 RECOMMENDED CALIBRATION FRE-

QUENCY

Provided that the instrument remains in continuous operation with power on, it is necessary only to calibrate once a week, by the procedure of Section 3-4 on page 3-2.

To restart the analyzer after power turn-off, repeat the startup procedure of Section 3-3 on page 3-1 and calibrate per Section 3-4 on page 3-2.

3-7 SHUTDOWN

Instruction Manual

748221-M

July 2002

Before turning off sample gas, and flowing reference gas, if used, disconnect power from the analyzer. This precaution minimizes the risk of filament damage.

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

Instruction Manual

748221-M July 2002

Model 7D

3-4 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7D

Instruction Manual

748221-M

July 2002

SECTION 4

THEORY

4-1 THERMAL CONDUCTIVITY CELL AND AS-

SOCIATED BRIDGE ADJUSTMENTS

Within the thermal conductivity cell are four resistive filaments suspended in individual cavities of a metal block (Figure 4-1A on page 4-3) and connected electrically as legs of a Wheatstone bridge (Figure 4-1B on page 4-3). Although physically the cell block is one piece, functionally it may be considered to have two sides as shown:

Sample Side

Two filaments that constitute opposite legs of the bridge are positioned in a passage that receives a continuous flow of the sample gas.

Reference Side

The remaining two filaments are positioned in a passage filled with the reference gas. Depending on the application, the reference gas may flow continuously through the passage, or it may be sealed within the cell.

resultant change in filament resistance unbalances the bridge.

The bridge-imbalance signal is routed to the Master Board (PN 654620), where it is processed to drive the front -panel meter and recording device, if used (see Section 4-2a below).

Periodically, downscale calibration gas is passed through the cell, and the front panel ZERO Pot is adjusted for an appropriate reading on the m eter or recorder.

4-2 ELECTRONIC CIRCUITRY

Electronic circuitry of the Model 7D is shown in the schematic diagram of drawing 654616. Internal circuitry of plug-in boards and other electronic assemblies is shown in separate schematic diagrams, found at the end of this manual, and is described in the following sections.

a. Master Board

The Bridge Voltage Power Supply (PN

613560) is connected, via a 20-ohm dropping resistor, to the bridge (See Section 4-2d on page 4-4). The power supply output is adjusted to provide an appropriate voltage across bridge terminals 1(+) and 2(-). An electric current flows through the filaments, heating them and thus increasing their electrical resistance. The heat -dissipation rate for each filament depends on the thermal conductivity of the surrounding gas. Initially, with downscale calibration gas flowing through the sample and reference sides of the flow-through configuration, R26 is set for zero bridge-output signal. During subsequent analysis of the sample stream, any change in the relative proportions of the components passing through the sample side changes the thermal conductivity of the gas mixture, causing a temperature differential between sample and reference filaments. The

Rosemount Analytical Inc. A Division of Emerson Process Management Theory 4-1

The Master Board (PN 654620), Figure 2-6 on page 2-8, provides two stages of amplification utilizing integrated-circuit amplifiers AR1 and AR2.

Functions Associated with AR1

AR1

Gain Adjust Potentiometer R4. This screwdriver-adjustable, factory -set trimming potentiometer determines feedback resistance for AR1 and thus permits adjustment of AR1 gain from X1 to X100. This adjustment sets the sensitivity for Range 1, i.e., the highest-sensitivity range.

Range Provisions

In the basic single-range Model 7D, a jumper is connected from TB3-1 to TB3-4, thus routing the unattenuated output from AR1 directly to the non-inverting input of

Instruction Manual

POSITION

748221-M July 2002

Model 7D

AR2. During factory assembly of a dual-range or triple-range instrument, the jumper is omitted and a front panel RANGE Switch is connected as shown below. The output from AR1 is then routed to AR2 through a network that provides adjustable attenuation for ranges 2 and 3.

RANGE

Table 4-1. Range Switch Connections

AR1 OUTPUT

ATTENUATION

1 X1, fixed 1 1 2 adjustable by R7 2 2 3 adjustable by R9 3 3

Coarse zero and zero-suppression

Pots R26, R6 or R8, depending upon range number, provide the zero correction at the non-inverting input of AR1.

Functions Associated with AR2

AR2 Zero Adjustment Potentiometer R1

This screwdriver-adjustable, factory -set trimming potentiometer is used to eliminate voltage offset within AR2. When the input signal is zero, R15 is adjusted so that the output signal also is zero.

RANGE

SWITCH

wiper 4

TB3

POSITION

Front-Panel M eter

The meter is connected from TB3-7 to TB3-8. Potentiometer R22 permits adjusting meter sensitivity so that meter fullscale agrees with recorder fullscale.

Output Selection Switch S1

The desired output is obtained by appropriate selection of switch contacts: 5V, 1V, .1V, or .01V.

b. Voltage Output Linearizer Board

(Optional)

The output signal from the Master Board is a function of the degree of imbalance in the bridge circuit, but is not linear with respect to the concentration of the measured component. Providing that the nonlinearity of the calibration curve does not exceed 20% at midscale (for 50 % H max.), the Voltage Output Linearizer Board (PN 633756) may be used to equip a given operating range for linear readout of concentration on the meter and on a potentiometric recorder.

Straightening of the concentration vs output curve is accomplished by sequential adjustment of eight odd numbered trimming potentiometers designated R19 through R33. Each pot controls the gain of an associated operational amplifier.

Front-Panel SPAN Control

This potentiometer, connected across TB3-5 and TB3-6, provides continuously variable adjustment of closed-loop gain for AR2, to permit establishing an upscale calibration point on the meter scale or recorder chart. With upscale calibration gas flowing through the analyzer, the SPAN Control is adjusted for the appropriate reading.

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

During factory checkout of a linearizer circuit board, potentiometers R19 through R33 are initially set at midrange. With zero input signal applied to the linearizer circuit, ZERO potentiometer R35 is adjusted for zero output. Then an appropriate low-level signal is applied to the input, and R19 is adjusted for fullscale output. The procedure is repeated as many times as required to obtain properly linearized output.

Model 7D

0.5

0.5200.5

0.534516782

B. F

A. SECTIONAL VIEW OF THERMAL CONDUCTIVITY CELL

Instruction Manual

748221-M

July 2002

Thermal Conductivity Cell Block

Sample Gas Out

Reference Filaments

Reference * Gas In

Sample Gas In

* Reference Ports Capped if Cell Uses Sealed-In, Non-Flowing Reference Gas.

UNCTIONAL DIAGRAM OF BRIDGE CIRCUIT

Front Panel Zero Potentiometer

O-Ring Seals

Sample Filaments

NOTE: Cell Block Sectioned Through Sample Side. Section Through Reference side is Similar.

Reference Flow

Resistor values are in ohms.

Sample Flow

Bridge Power

Supply (+)

Bridge Power

Supply (-)

Figure 4-1. Thermal Conductivity Cell

Rosemount Analytical Inc. A Division of Emerson Process Management Theory 4-3

Instruction Manual

748221-M July 2002

Model 7D

c. Isolated 4 to 20 mA Current Output

Board (Optional)

This option provides isolated current output for applications which require 4 to 20 mA into a maximum load of 1500 ohms. This output is NOT linearized. A description of the board and the functions of its main components follows. Refer to schematic 652813 at the rear of this manual.

The purpose of the Isolated Current Output Board (PN 625816) is to convert an input signal of 0 to -5 V to an isolated output signal of 4 to 20 mA. With a zero voltage at the input, R6 is adjusted so that the output at AR1 is 1 V. The gain of AR1 is .8 so that an input of 0 to -5 V is converted to 1 to 5 V. This voltage is fed to a variable output level-inverter consisting of AR2, Q1, Q2, and T1. T1 has two identical output windings, each with a rectified DC output. One is used to provide feedback to the inverter input of AR2. The other is used as an isolated output to drive AR3 and Q3 with a 1 to 5 V signal across R16. Trim-pot R17 is adjusted to provide a span of 4 to 20 mA. This current is presented to the collector of Q3 and is capable of driving loads of up to 1500 ohms.

e. ±15 Volt Power Supply

The ±15 Volt Power Supply (PN 619714) plugged into J101 of the Master Board, provides power for the various circuits. As shown in drawing 619710, power transformer T1 has three secondary that are used as follows:

38 VAC center-tapped secondary

Powers both 15 volt supplies through diode bridge CR1 and filter capacitors C1 and C4.

The adjustable positive regulator, VR1, is set by voltage divider R1, R2 and R3 and its output is applied to pin A of the circuit board and to test point TP1. Potentiometer R2 should be adjusted to +15.5 VDC ±50 mVDC.

The negative DC, regulated by VR2 is applied to pin D of the circuit board.

The center tap is the common reference for both the +15 and -15 volt supplies and is applied to pin R of the circuit board and to test point TP2.

Both outputs are used for individual amplifiers on the various circuit boards.

d. Bridge Power Supply

The regulated, adjustable voltage required for the thermal conductivity bridge (Section 4-1 on page 4-1) is provided by the Bridge Power Supply (PN

613560). It consists of a power transformer, fullwave rectifiers CR1 and CR2, voltage regulator Q1, and an RC filter network. Bridge voltage, as measured between bridge terminals 1(+) and 2(-), is adjustable from 5 to 13 VDC via R2. Proper setting depends primarily on filament material: 3 to 4 VDC for tungsten; 5 to 12 VDC for Hitempco. Bridge voltage is factory -set as required for the application (see Data Sheet in the rear of this manual) and normally does not require readjustment unless the power supply is replaced.

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

90-volt center-tapped secondary

Drives a rectifier circuit on the optional Current Output Board (PN 652816). The transformer winding and the associated circuit constitute a floating power supply for the emitter-follower stage. Refer to Section 4-2c above.

9.5 VAC secondary

Drives a +5 VDC supply not used in this instrument.

f. Detector Blocks

There are two types of detector configurations; flowing reference and sealed nitrogen reference. The sealed reference with nitrogen can be recharged by flowing nitrogen through the reference

Model 7D

Instruction Manual

748221-M

July 2002

and closing the plugs. Three filament types are available: tungsten, Hitempco, and gold-sheathed tungsten.

g. Case Temperature Controller

Assembly

The case Temperature Controller Assembly (PN 652270) maintains an approximate 117 °F (47°C) temperature within the instrument.

Changes in case temperature affect the resistance of the sensor connected to J18. This in turn changes the bias of amplifier AR1, which controls the input to the case heater via switch U2. The heater receives power through pins 3, 4 and/or 5, depending on the voltage selected at switch S3. A thermal fuse at J5 prevents the case from overheating.

h. Dual Alarms (Option)

Instruments with optional Dual Alarms have two pots on the front door which are

used to select setpoints. The scales on the nameplate designate setpoints from 0 to 100%.

The alarm module is shown in Figure 6-2 on page 6-5, and the factory connections are shown in drawing 654642. The module plugs into a socket, which is part of a terminal block mounted onto the chassis of the instrument. A marker on the alarm module indicates the function of each socket pin.

This unit is factory configured and requires no user adjustment. Pins for AC power (1, 2, and 3), alarm setpoint control (8, 10, 18, and 19), and signal from analyzer circuitry (7 and 9) are wired at the factory.

Connections of the remaining pins depend upon the application. The relays are rated at 1.0 A, 120 VAC and 5.0 A, 120 VDC, form C, resistive loads.

Rosemount Analytical Inc. A Division of Emerson Process Management Theory 4-5

Instruction Manual

748221-M July 2002

Model 7D

4-6 Theory Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7D

Instruction Manual

748221-M

July 2002

SECTION 5

SERVICE AND MAINTENANCE

WARNING

POSSIBLE EXPLOSION HAZARD

If explosive gases are introduced into this analyzer, the sample containment system must be carefully leak-checked upon installation and before initial startup, during routine maintenance and any time the integrity of the sample containment system is broken, to ensure the system is in leakproof condition. Leak-check instructions are provided in Section 2-4 on page 2-3.

Internal leaks resulting from failure to observe these precautions could result in an explosion causing death, personal injury or property damage.

In troubleshooting, the basic approach is to isolate the analyzer from the sample and the sample-handling system.

First admit downscale and upscale standard gases to analyzer and note response:

1. If performance is normal with standard gases, although not with sample gas, the sample and the sample-handling system are suspect. Check these areas.

2. If analyzer gives offscale or erratic readings with standard gases, as well as with sample gas, the problem might be the filaments or the electronic circuitry. To isolate the malfunction, substitute fixed precision resistors of appropriate value for the filaments. Hitempco filaments (P/N 25499) have a cold resistance of 72 ohms. Tungsten filaments (P/N 811993) have a cold resistance of 18 ohms. Filament connections are shown in drawing

654616. With appropriate resistors substituted for the filaments, attempt to balance the bridge as follows:

a. If bridge balance is obtained with the

fixed resistors, the filaments are probably defective and should be replaced.

b. If bridge balance is unobtainable with

the fixed resistors, the problem might be the electronic circuitry. Substitute each circuit board, in turn, until proper operation is obtained.

5-1 THERMAL CONDUCTIVITY CELL

The thermal conductivity cell and associated elements of the bridge are mounted inside the analyzer case, within a thermally-insulated compartment.

Depending on the bridge current level, the filaments gradually become mismatched, and eventually burn out. Normal progression of symptoms is baseline drift. Sealed reference cells must be serviced by the factory.

If the cell uses flowing reference gas, the filaments may be replaced by the user. Refer to Figure 4-1 on page 4-3 and the parts list in Section 6.

Filaments are sold as matched sets. If one must be replaced, its mate also must be replaced. Electrically, the filaments are mated across the diagonals of the cell. Refer to Figure 4-1B. The filament across points 3 and 1 corresponds to the filament across 8 and 1, and the filament across points 6 and 2 corresponds to the filament across 5 and 2.

5-2 ELECTRONIC CIRCUITRY

a. Amplifier Zero Adjustments

The zero adjustments on the Master Board are factory set and normally do not require readjustment except after replacement of a major component. If

Rosemount Analytical Inc. A Division of Emerson Process Management Service and Maintenance 5-1

Instruction Manual

748221-M July 2002

Model 7D

readjustment becomes necessary, use following procedure:

AR2 Zero Adjustment:

1. Open the input to AR2. In a single-range instrument, this is done by disconnecting the jumper from TB3-1 to TB3-4.

2. Ground the input of AR2 by connecting a jumper from TB3-4 to TP1 (GND).

3. Adjust R15, (Figure 2-6 on page 2-8 ), for 0 VDC output signal at TB4-2.

4. Restore connections to normal.

b. Bridge Balance and Range Sensitivity

Adjustments

Perform start -up procedure in Section 3-3 on page 3-1, then proceed as follows:

1. On the analyzer module, set the front panel ZERO and SPAN potentiometers to their midpoints (five turns). If the analyzer has a front panel RANGE Switch, set it to Range 1, the highest-sensitivity range.

2. Admit downscale calibration gas to the analyzer at the same flow rate as is used for the sample gas. Wait for the reading on the meter or recorder to stabilize.

3. Refer to Figure 2-6 on page 2-8 and set the Balance Adjustment on the Master Board, (range 1 or single range R8, range 2 R6, range 3 R26) so that the reading on the meter or recorder is zero or an offset value. Refer to Data Sheet in the rear of this manual.

Sensitivity Adjustment(s) are:

1. Admit upscale calibration gas to the analyzer at the same flow rate as is used for the sample gas. Wait for reading on meter or recorder to stabilize.

2. On the Master Board, set AR2 Gain Adjustment R4 so that reading on the recorder, if used, or on the front -panel meter is appropriate to the upscale calibration gas. Refer to Data Sheet in the rear of this manual or calibration curve. Range 1 sensitivity is now properly adjusted.

3. If analyzer has more than one range, set the front panel RANGE Switch for Range 2. This is the reduced sensitivity range. Then, on the Master Board, set Range 2 Attenuation Adjustment R7 so that the reading on the recorder, if used, or on the front panel meter is appropriate to the upscale calibration gas.

4. If the analyzer has three ranges, set the front panel RANGE Switch for Range 3. This is the least sensitive range. Then, on the Master Board, set Range 3 Attenuation Adjustment R9 so that the reading on the recorder, if used, or on the front panel meter is appropriate to the upscale calibration gas.

5. If previous readings were obtained on a recorder, set the Meter 100% Adjustment R22 so that the meter fullscale matches the recorder fullscale. If the analyzer has more than one range, this adjustment should be made on Range 1.

c. Bridge Voltage Adjustment

Bridge voltage is factory set as required for the application (see Data Sheet in the rear of this manual) and normally does not require readjustment unless the bridge power supply is replaced. Bridge voltage is measured between terminals 1(-) and 2(+), and is adjustable via R2, DWG 613561, on the bridge power supply.

5-2 Service and Maintenance Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7D

Instruction Manual

748221-M

July 2002

d. Case Temperature Controller

Refer to Figure 6-3 on page 6-6. Malfunction in this option can occur in three areas:

Heater

Check continuity with ohmmeter. Verify that resistance is approximately 113 ohms at 25°C.

Temperature Sensor

This is an RTD and should have approximately 550 ohms at 25°C. Check for continuity with ohmmeter.

Thermal Fuse

The fuse opens at temperatures above 72°C. Check continuity with ohmmeter.

e. Dual Alarm Module (Optional)

This module is not user-serviceable. If problems occur, contact Rosemount Analytical Customer Service Center (see page 7-1).

The module has Zero and Span potentiometers that set the 0 to 5 V input. To check these, adjust the analyzer for zero gas, set the Low Alarm (ALARM 1 on the front panel) set point to 0 %, and turn the Deadband counterclockwise. Adjust the Zero pot to trigger the alarm. Do the same for High Alarm (ALARM 2 on the front panel). The alarm span should agree with the analyzer meter span. Readjust the deadbands to the desired level. (See Figure 2-7 on page 2-9 and Figure 2-8 on page 2-11.)

5-3 SUPPRESSED ZERO ADJUSTMENT

If the instrument has suppressed-zero ranges and does not calibrate properly, adjust the potentiometers located on the Master Board (see Figure 2-6 on page 2-8). Follow the startup procedure in Section 3-3 on page 3-1. After the analyzer has stabilized, use

appropriate calibration gases to make the following adjustments. Refer to Section 2-3b on page 2-1 for information on selecting appropriate gases.

NOTE

For instruments with more than one range, RANGE 1 is the most sensitive range; it must be set for the highest gain. This range should be used for the smallest span. Always start procedure with RANGE 1 (i.e., RANGE 1 ... 95 to 100%, RANGE 2 ... 90 to 100%, RANGE 3 ... 60 to 80%).

1. Set the front panel ZERO and SPAN pots to their midpoints (five turns).

2. If the instrument has a Range Switch, set it to RANGE 1.

3. Connect a digital voltmeter between TB3-1 and TP1 (polarity does not matter).

4. Flow downscale calibration gas through the sample inlet of the analyzer. Adjust R8 until the reading on the voltmeter is zero. The front panel meter should also read zero.

5. Flow upscale calibration gas through the sample inlet of the instrument. Adjust R4 until the front panel meter reads 100 % (fullscale).

6. Repeat steps 4 and 5 above until no adjustment is required.

If the analyzer has more than one range, repeat steps 2 through 6 with the following alterations:

Range 2

Set the Range Switch to RANGE 2. In step 4, adjust R6, and in step 5, adjust R7.

Range 3

Set the Range Switch to RANGE 3. In step 4, adjust R26, and in step 5, adjust R9.

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

Instruction Manual

748221-M July 2002

Model 7D

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

Model 7D

Instruction Manual

748221-M

July 2002

SECTION 6

REPLACEMENT PARTS

WARNING

PARTS INTEGRITY

Tampering with or unauthorized substitution of components may adversely affect safety of this product. Use only factory-approved components for repair.

6-1 CIRCUIT BOARD REPLACEMENT POLICY

In most situations involving a malfunction of a circuit board, it is more practical to replace the board than to attempt isolation and replacement of the individual component, as the cost of test and replacement will exceed the cost of a rebuilt assembly. As standard policy, rebuilt boards are available on an exchange basis.

Because of the exchange policy covering circuit boards, the following list does not include individual electronic components. If circumstances necessitate replacement of an individual component, which can be identified by inspection or from the schematic diagrams, obtain the replacement component from a local source of supply.

6-2 REPLACEMENT PARTS

The following parts are recommended for routine maintenance and troubleshooting of the Model 7D. If the troubleshooting procedures do not resolve the problem, contact Rosemount Analytical Customer Service Center (see page 7-1).

Figure 6-1 through Figure 6-3 show locations of components and assemblies.

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 6-1

Instruction Manual

654648

1,2

Alarm Kit (Section

6-2c

)

619714

15V Power Supply (

Figure

6-2

)

654628

Detector Assembly w/Filaments - Flowing Ref (Tungsten) (

Figure

4-1

)

654629

1,3

Detector Assembly w/Filaments - Sealed Ref Nitrogen (Hytempco)

902442

Filaments (Tungsten) (

Figure

4-1

)

000516

Fuse 3A (115VAC) (

Figure

6-2

)

654620

Master Board (

Figure

6-2

)

901917

ZERO Potentiometer (

Figure

6-1

)

748221-M July 2002

a. Selected Replacement Parts

Model 7D

652270 654892

1,2

Temperature Control Assembly (Section 6-2b)

1,2

Range Switch Kit (Section 6-2d)

613560 Bridge Power Supply (Figure 6-2) 654632

654630 654627

654631 902444

902443 638426 Flame Arrestor (Figure 6-1)

801566 652816

616443

Detector Assembly w/Filaments - Flowing Ref (Gold Sheathed Tungsten) (Figure 4-1)

Detector Assembly w/Filaments - Flowing Ref (Hytempco) (Figure 4-1)

1,3

Detector Assembly w/Filaments - Sealed Ref (Tungsten)

1,3

Detector Assembly w/Filaments - Sealed Ref Nitrogen (Gold Sheathed Tungsten)

Filaments (Gold Sheathed Tungsten) (Figure 4-1)

Filaments (Hytempco) (Figure 4-1)

Fuse 1.5A (230VAC) (Figure 6-2)

Isolated Current Output Board (Figure 6-2)

Linearizer Kit (Factory Installed option. Consult factory.) (Figure 6-2)

193311 Meter (Figure 6-1) 898672 SPAN Potentiometer (Figure 6-1)

b. Temperature Control Assembly

Refer to Figure 6-3.

622733 Fan 622732 Heater 624006 Temperature Control Board 622917 Temperature Sensor 624433 Thermal Fuse

c. Alarm Option

Refer to Figure 6-1 and Figure 6-2.

901916 Socket, 20 Pin 901913 Dual Alarm Module 901918 Variable Resistor 1K ohm

d. Range Switch Kit

Refer to Figure 6-1 and Figure 6-2.

633899 Switch

Parts are selected or are optional depending on instrument application. Refer to Application Data Sheet and ordering info r-

mation to determine which parts are applicable to your instrument.

Refer to section listed for replacement parts of assembly.

Sealed reference cells must be serviced at factory.

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

Model 7D

Hydrogen in Carbon Dioxide

Instruction Manual

748221-M

July 2002

6-3 MATRIX

Each analyzer is configured per the customer sales order. Below is the Model 7D sales matrix which lists the various configurations available.

7D MODEL 7D TC ANALYZER (EXPLOSION PROOF ENCLOSURE)

Parameter and Background Gas

Code Code

10 Hydrogen in Air 21 Helium in Nitrogen 11 Hydrogen in Nitrogen 22 Helium in Oxygen 12 Hydrogen in Methane 23 Helium in Methane 13 Hydrogen in Argon 24 Helium in Argon 14 20 Helium in Air 26 Helium in Argon & Oxygen 50 Nitrogen in Hydrogen (0-5000 ppm Range Only) Range Code #31 60 Refinery (15% Hydrocarbon - 85% N2; 100% N2; 1% Hydrogen in 99% N2) Range Code #60 61 Utilities (BD Special) (80-100% H2 in Air, 0-100% H2 in CO2 and 0-100% Air in CO2) Range Code #61 90 Argon in Air 91 Argon in Nitrogen 92 Argon in Oxygen 93 Carbon Dioxide in Air 94 Carbon Dioxide in Nitrogen 95 Carbon Dioxide in Oxygen 96 Nitrogen in Argon 97 Corrosive Gas Mixture Application (Zero Based Ranges Only) Range Code #97 98 Corrosive Gas Mixture Application (Suppressed Range Only) Range Code #98 99 Special

Code Range

14 85-100% X X X 15 95-100% X X X 16 99-100% X X X 17 99.5%-100% X X X 19 Special Suppressed Range 30 0-500 ppm X X X 31 0-5000 ppm X X X 01 0-1% X X X 02 0-5% X X X 03 0-10% X X X 04 0-15% X X X 05 0-25% X X X 06 0-50% X X X 07 0-75% X X X 08 0-100% X X X 09 Special Zero Based Range 10 20-50% X X X 11 45-55% X X X 12 60-80% X X X 13 50-100% X X X 60 Refinery X X X 61 Utilities X X X 97 Corrosive Gas Mixture - Application Zero Based Range X Gold Sheathed 98 Corrosive Gas Mixture - Application Suppressed Range X Gold Sheathed

Code Single & Dual Range Analyzer

01 One Range, Voltage Output 02 One Range, Linearized Voltage Output 03 One Range with 4-20 mA, Isolated Current Output 04 One Range, Linearized and 4-20 mA, Isolated Current Output 05 Two Ranges, Voltage Output 06 Two Ranges, Range One Linearized Voltage Output

Code Second Range: Dual Range Analyzer

XX Range Selections same as position 5, 6; 00 if second range is not selected.

7D 12 03 02 00 03 Example

1,2 3,4 5,6 7,8 9,10 11,12 Matrix positions

25 Helium in Carbon Dioxide

Code Power, Alarm, Tropicalization

01 115V, 50/60 Hz 02 115V, 50/60 Hz with Dual Alarm 03 115V, 50/60 Hz with Tropicalization 04 115V, 50/60 Hz with Dual Alarm and Tropicalization 05 230V, 50/60 Hz 06 230V, 50/60 Hz with Dual Alarm 07 230V, 50/60 Hz with Tropicalization 08 230V, 50/60 Hz with Dual Alarm and Tropicalization

Not

Applicable

To identify the configuration of an analyzer, locate the analyzer name-rating plate. The sales matrix identifier number appears on the analyzer name-rating plate.

Linearization Reference Filament

Optional

Not

Available

Sealed Flowing Tungsten Hytempco

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 6-3

Instruction Manual

898672

(Kit 654648)

638426

748221-M July 2002

Model 7D

193311 Meter

REF Hinge Side

Flame Arrestor

ALARM 1 Potentiometer (Kit 654648)

RANGE Switch (Kit 654892)

ALARM 2 Potentiometer

ZERO Potentiometer 901917

SPAN Potentiometer

Figure 6-1. Analyzer Assembly - Door and Pneumatic Components

6-4 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA 2000 TO2

Alarm Kit

15V Power Supply

Linearizer Board (option)

Isolated Current Output Board

Bridge Power Supply

Fuse

Temperature Control Assembly

Master Board

652816

Instruction Manual

748221-M

July 2002

616443

652270

654620

619714

613560

REF Hinge Side

000516 (115 VAC) 801566 (230 VAC)

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 6-5

Cell Enclosure

654648

Figure 6-2. Analyzer Assembly - Electronic Components

Instruction Manual

622732

622733

Sensor 622917

624433

(Ref)

748221-M July 2002

Model 7D

Temperature Control Board 624006

Thermal Fuse

Sensor 622917

Fan Assembly

Heater Assembly

Figure 6-3. Temperature Control Assembly

6-6 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA 2000 TO2

RETURN OF MATERIAL

Instruction Manual

748221-M

July 2002

SECTION 7

7-1 RETURN OF MATERIAL

If factory repair of defective equipment is required, proceed as follows:

1. Secure a return authorization from a Rosemount Analytical Inc. Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted.

Rosemount CSC will provide the shipping address for your instrument.

In no event will Rosemount be responsible for equipment returned without proper authorization and identification.

2. Carefully pack the defective unit in a sturdy box with sufficient shock absorbing material to ensure no additional damage occurs during shipping.

3. In a cover letter, describe completely:

• The symptoms that determined the

equipment is faulty.

• The environment in which the

equipment was operating (housing, weather, vibr ation, dust, etc.).

• Site from where the equipment was

removed.

• Whether warranty or non-warranty

service is expected.

• Complete shipping instructions for the

return of the equipment.

4. Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in the Rosemount Return Authorization, prepaid, to the address provided by Rosemount CSC.

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

If warranty service is expected, the defective unit will be carefully inspected and tested at the factory. If the failure was due to the conditions listed in the standard Rosemount warranty, the defective unit will be repaired or replaced at Rosemount’s option, and an operating unit will be returned to the customer in accordance with the shipping instructions furnished in the cover letter.

For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions.

7-2 CUSTOMER SERVICE

For order administration, replacement Parts, application assistance, on-site or factory repair, service or maintenance contract information, contact:

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

7-3 TRAINING

A comprehensive Factory Training Program of operator and service classes is available. For a copy of the Current Operator and Service Training Schedule contact the Technical Services Department at:

Rosemount Analytical Inc.

Customer Service Center

1-800-433-6076

Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 7-1

Instruction Manual

748221-M July 2002

Model 7D

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

WARRANTY

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, part(s) and consumables are capable of being renewed, repaired or replaced.

The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any other cause. All other warranties, expressed or implied are hereby excluded.

IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER.

Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond Seller's direct control.

Instruction Manual

Emerson Process Management

ASIA - PACIFIC

Fisher-Rosemount GmbH & Co.

EUROPE, MIDDLE EAST, AFRICA

West Sussex PO22 9SH

LATIN AMERICA

748221-M July 2002

Model 7D

Rosemount Analytical Inc. Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com

Fisher-Rosemount Singapore Private Ltd.

1 Pandan Crescent Singapore 128461 Republic of Singapore T 65-777-8211 F 65-777-0947

http://www.processanalytic.com

Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0

F 49-6055-884209

Fisher-Rosemount Ltd.

Heath Place Bognor Regis

England T 44-1243-863121

F 44-1243-845354

Fisher - Rosemount

Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003

T 55-21-2431-1882

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