Instruction Manual
748175-G
May 2002
Model 815
Explosion Proof Non-Dispersive Infrared Analyzer
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and
international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them 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 and Viton are registered trademarks of E.I. duPont de Nemours and Co., Inc.
Irtran is a trademark of Eastman Kodak Co.
Pyrex is a registered trademark of Corning Glass Works
SNOOP is a registered trademark of NUPRO Co.
Emerson Process Management
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 815
PREFACE................................................................................................................................P-1
Definitions ................................................................................................................................P-1
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 General Description ......................................................................................................1-1
1-2 Applications..................................................................................................................1-1
1-3 Available Options..........................................................................................................1-2
1-4 Specifications ...............................................................................................................1-3
2-0 INSTALLATION...........................................................................................................2-1
2-1 Unpacking....................................................................................................................2-1
2-2 Location .......................................................................................................................2-1
2-3 Voltage requirements....................................................................................................2-1
2-4 Electrical Connections...................................................................................................2-1
a. Line Power Connections ..........................................................................................2-1
b. Recorder Connections .............................................................................................2-1
2-5 Sample Connections .....................................................................................................2-2
2-6 Calibration Gas Connections and Requirements.............................................................2-2
2-7 Sample Handling System..............................................................................................2-4
2-8 Leak Test .....................................................................................................................2-4
2-9 Options ........................................................................................................................2-5
a. Air Purge Kit 652271...............................................................................................2-5
b. Current Output Kit 652269.......................................................................................2-5
c. Case Heater Temperature Control Kit 652270...........................................................2-5
d. Linearizer Kit 652268 ..............................................................................................2-7
e. Motor/Source Assembly Purge Kit 655094 ................................................................2-8
Instruction Manual
748175-G
May 2002
TABLE OF CONTENTS
3-0 OPERATION................................................................................................................3-1
3-1 Initial Startup................................................................................................................3-1
a. Power Verification...................................................................................................3-1
b. Operating Controls and Indicators............................................................................3-1
Digital Display .........................................................................................................3-1
MODE Switch .........................................................................................................3-1
ZERO Adjustment...................................................................................................3-2
SPAN Adjustment ...................................................................................................3-2
3-2 Calibration....................................................................................................................3-3
a. Calibration Procedure..............................................................................................3-3
b. Linearizer Board Calibration.....................................................................................3-3
c. Calibration Curve Construction................................................................................3-4
3-3 Linearization procedure.................................................................................................3-7
3-4 Current Output ..............................................................................................................3-9
3-5 Routine Operation .........................................................................................................3-9
3-6 Recommended Calibration Frequency............................................................................3-9
3-7 Shutdown.....................................................................................................................3-9
Rosemount Analytical Inc. A Division of Emerson Process Management Contents i
Instruction Manual
748175-G
May 2002
4-0 THEORY......................................................................................................................4-1
4-1 Detection System Theory ..............................................................................................4-1
4-2 Electronic Circuitry........................................................................................................4-2
a. Oscillator Circuit Board (Schematic 623995) and Associated Elements of Amplitude
Modulation Circuit ...................................................................................................4-2
b. Functioning of Modulation System in TUNE Mode .....................................................4-2
c. Functioning of Modulation System in Operating Mode ...............................................4-2
d. Radio-Frequency Demodulator ................................................................................4-3
e. Signal Board (Schematic 652431)............................................................................4-3
f. Power Supply Board (Schematic 624073).................................................................4-3
g. Case Heater Temperature Control Board (Schematic 624003) ...................................4-3
h. Current Output Board (Schematic 652439) ...............................................................4-3
i. Linearizer Board (Schematic 624674).......................................................................4-4
5-0 TROUBLESHOOTING..................................................................................................5-1
5-1 Symptom Chart .............................................................................................................5-1
5-2 Test Equipment ............................................................................................................5-1
5-3 Voltage Checks ............................................................................................................5-1
5-4 Oscillator Tune Adjustment............................................................................................5-1
5-5 Preamp Gain ................................................................................................................5-2
a. Peak Adjus Tment....................................................................................................5-2
5-6 Source Balance Shutter Adjustment...............................................................................5-2
5-7 Source Alignment .........................................................................................................5-4
5-8 Source Current Adjustment ............................................................................................5-6
5-9 Time Constant ..............................................................................................................5-6
5-10 Case Heater Temperature Control Assembly ..................................................................5-6
Model 815
6-0 ROUTINE SERVICING..................................................................................................6-1
6-1 Cell Removal, Cleaning and Replacement......................................................................6-1
a. Long Cell Configurations .........................................................................................6-1
b. Short Cell Configurations .........................................................................................6-2
6-2 Cell Desiccant ..............................................................................................................6-4
a. Desiccant Replacement ...........................................................................................6-4
6-3 Source Replacement .....................................................................................................6-4
6-4 Chopper Motor Assembly..............................................................................................6-5
a. Long Cell Configurations .........................................................................................6-5
b. Short Cell Configurations .........................................................................................6-5
6-5 Detector Replacement ...................................................................................................6-6
a. Removal - Long Cell Configurations .........................................................................6-6
b. Removal - Short Cell Configurations .........................................................................6-6
c. Detector Installation ................................................................................................6-6
7-0 REPLACEMENT PARTS..............................................................................................7-1
7-1 Circuit Board Replacement Policy ..................................................................................7-1
7-2 Selected Replacement Parts .........................................................................................7-1
a. Model 815 Common Parts .......................................................................................7-1
b. Optical Bench .........................................................................................................7-1
7-3 Option Kits ...................................................................................................................7-2
a. Linearizer Kit PN 652268 .........................................................................................7-2
b. Current Output Kit PN 652269 .................................................................................7-2
c. Case Heater Temperature Control Kit PN 652270.....................................................7-2
d. Air Purge Kit PN 652271..........................................................................................7-2
e. Motor/Source Purge Kit PN 655094..........................................................................7-2
ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model 815
8-0 RETURN OF MATERIAL ..............................................................................................8-1
8-1 Return Of Material.........................................................................................................8-1
8-2 Customer Service.........................................................................................................8-1
8-3 Training........................................................................................................................8-1
Figure 1-1. Model 815 Explosion Proof NDIR Analyzer.......................................................1-1
Figure 2-1. Model 815 Component Locations.....................................................................2-2
Figure 2-2. Power Supply Board.......................................................................................2-3
Figure 2-3. Case Heater Temperature Control Board..........................................................2-3
Figure 2-4. Current Output Board......................................................................................2-6
Figure 2-5. Installation of Current Output and Temperature Control Options .........................2-6
Figure 2-6. Linearizer Board.............................................................................................2-7
Figure 2-7. Signal Board with Linearizer Board Installed .....................................................2-7
Figure 3-1. Model 815 Operating Controls and Indicators ...................................................3-2
Figure 3-2. Signal Board Component Locations .................................................................3-5
Figure 3-3. Linearizer Board Adjustments ..........................................................................3-6
Figure 3-4. Typical Linearization Curve..............................................................................3-6
Figure 3-5. Current Output Board......................................................................................3-9
Figure 4-1. NDIR Detection System ..................................................................................4-1
Figure 4-2. Functional Block Diagram ................................................................................4-4
Figure 5-1. Modulation System .........................................................................................5-5
Figure 6-1. Optical Bench .................................................................................................6-3
Figure 6-2. Motor/Source Assembly ..................................................................................6-5
Figure 6-3. Detector Replacement .....................................................................................6-7
Figure 7-1. Configurations 06, 07, 11, 19, 21, 31, 36, 41, 45, 54, 71, 72, 81.........................7-3
Figure 7-2. Configurations 35, 73......................................................................................7-3
Figure 7-3. Configurations 64, 83......................................................................................7-4
Figure 7-4. Configuration 08, 10, 12, 13, 18, 32, 39, 42, 43, 55, 63, 65, 67...........................7-4
Figure 7-5. Configurations 22, 23, 29, 30, 33, 34, 38, 76 .....................................................7-5
Figure 7-6. Configuration 26.............................................................................................7-5
Figure 7-7. Configurations 74, 82, 84.................................................................................7-6
Figure 7-8. Case Heater Temperature Control Assembly ....................................................7-9
Instruction Manual
748175-G
May 2002
LIST OF ILLUSTRATIONS
LIST OF TABLES
Table 3-1. Typical Linearization Calibration Values ...........................................................3-8
Table 3-2. Linearization Calibration Values.......................................................................3-8
Table 5-1. Troubleshooting Chart.....................................................................................5-3
Table 6-1. Types of Desiccant .........................................................................................6-4
Table 7-1. Configuration Figure List .................................................................................7-2
Table 7-2. Optical Bench Components by Configuration....................................................7-6
Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii
Instruction Manual
748175-G
May 2002
LIST OF DRAWINGS (LOCATED IN REAR OF MANUAL)
623995 Schematic Diagram, Oscillator Board
624003 Schematic Diagram, Temperature Control Board
624073 Schematic Diagram, Power Supply Board
624674 Schematic Diagram, Linearizer Board
652258 Installation Drawing, Model 815
652259 Pictorial Wiring Diagram, Model 815
652431 Schematic Diagram, Signal Board
652439 Schematic Diagram, Current Output Board
652446 Schematic Diagram, Zero/Span Control Board
Infrared Calibration and Data Sheet (per application)
Model 815
iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model 815
PREFACE
The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of the Model 815.
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 .
748175-G
May 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
748175-G
May 2002
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
Model 815
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.
This instrument is shipped from the factory set up to operate on 115 volt, 50/60 Hz electric power.
For operation on 230 volt, 50/60 Hz power, see Section 2-3 (page 2-1), Figure 2-2 (page 2-3), and
Figure 2-3 (page 2-3) for modifications.
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 instrument explosion-proof enclosure must be suitable for the gas.
WARNING .
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 2-8 (page 2-4).
Do not operate the Model 815 Explosion-Proof Analyzer without lens cover and door in place with
all bolts secured, unless location has been determined to be non-hazardous.
P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model 815
WARNING .
HIGH PRESSURE GAS CYLINDERS
This analyzer requires periodic calibration with known zero and standard gases. Refer to General
Precautions for Handling and Storing High Pressure 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.
748175-G
May 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3
Instruction Manual
748175-G
May 2002
Model 815
GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH
PRESSURE GAS CYLINDERS
Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed
Gases" published in 1981
Compressed Gas Association
1235 Jefferson Davis Highway
Arlington, Virginia 22202
Used by Permission
1. Never drop cylinders or permit them to strike each other violently.
2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather
and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when
located in areas where extreme 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 815
DOCUMENTATION
The following Model 815 instruction materials are available. Contact Customer Service Center or the local
representative to order.
748175 Instruction Manual (this document)
COMPLIANCES
The Model 815 Explosion Proof Non-Dispersive Infrared Analyzer is approved by Factory Mutual for use in
Class I, Groups B, C and D Division 1 hazardous locations.
748175-G
May 2002
FM
APPROVED
97-C209
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5
Instruction Manual
748175-G
May 2002
Model 815
P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model 815
Model 815
Instruction Manual
748175-G
May 2002
SECTION 1
DESCRIPTION AND SPECIFICATIONS
1-1 GENERAL DESCRIPTION
The Model 815 Non-Dispersive Infrared
Analyzer is designed to continuously
monitor the concentration of a particular
infrared absorbing component of interest in
a flowing gaseous mixture. Concentration is
displayed as a percent of fullscale. Signal
outputs of 0-5 VDC or 0-1 VDC are field
selectable standard.
The Analyzer enclosure is designed to
meet the requirements for Class I, Division
1, Groups B, C, and D, per the National
Electrical Code (ANSI/NFPA 70), and
should be mounted in a weather-protected
area.
1-2 APPLICATIONS
Monitoring applications are found in the
Application Data Sheet which is available
from the local sales office (see Section 8).
Some sample streams contain various
other infrared-absorbing substances, other
than the component of interest. To
minimize interference in such applications,
the instrument may incorporate an optical
filter and, if necessary, a sealed filter cell
containing an appropriate gas charge, as
noted in the Factory Calibration and Data
Sheet located in the rear of this manual.
ZERO SPAN
DETECTOR RANGE 1
TUNE RANGE 2
Rosemount Analytical
Oxygen Analyzer
Figure 1-1. Model 815 Explosion Proof NDIR Analyzer
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
748175-G
May 2002
Model 815
1-3 AVAILABLE OPTIONS
Operation of the Model 815 can be enhanced
with the choice of several options, all of which
can be installed in the field after the analyzer
has been ordered.
Signal Linearizer
A signal linearizer kit is available for each
range. Linearizers enable the operator to
convert non-linear output signals into linear
output signals.
Isolated Current Output
The current output option can be field set for
either 4-20mA or 0-20mA, corresponding to
0% to 100% of fullscale. Maximum load is
750 ohms.
Case Temperature Controller
A proportional temperature controller, with
heater and fan assembly, maintains proper
operating temperature inside the case.
Air Purge
The air purge kit is to be installed with
user-supplied components. It is designed for
use in cases where a corrosive gas is either
flowing through the cell or is present in the
environment. The air purge option is provided
for protection of the instrument only, and is
not intended as a safety feature for use in a
hazardous area.
Motor/Source Assembly Purge
This purge is recommended in some
applications to provide a CO2 free, spectrally
constant atmosphere within the Motor/Source
Assembly.
Sample Handling System Accessory
If so ordered, an associated sample-handling
system may be either factory-assembled or
supplied for field installation, depending on
ordering instructions. Sampling systems are
designed on the basis of information furnished
by the customer, which includes a complete
stream analysis. Refer to the Factory
Calibration and Data Sheet in the rear of this
manual for information on the sample
handling system.
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model 815
1-4 SPECIFICATIONS
Power Requirements..................... 120/220 VAC ±10%, 50/60 ±3 Hz, 150 W;
Ambient Temperature.................... 32°F to 113°F (0°C to 45°C)
Dimensions.................................... 21.5 in (55.0 cm) H
Weight ........................................... 119 lbs (54 kg)
Enclosure....................................... Explosion Proof, Class I, Groups B,C,D, Division 1.
Signal Output
Standard................................ 0-5 VDC (0-1 VDC field selectable on board)
Optional ................................. 4-20 mA or 0-20 mA (field selectable), 750 ohms max.
Repeatability.................................. 1% of fullscale
Noise ............................................. 1% of fullscale
Zero Drift
Span Drift
Response Time (Electronic).......... Variable, 90% of fullscale in 1 sec to 10 sec, field selectable.
Sample Cell Length....................... 0.04 in. (1 mm) to 10.0 in. (254 mm)
Reference Cell............................... Sealed
Materials in Contact with Sample
Sample Pressure........................... Max 10 psig (69 kPa), standard
1
1
Windows................................ Sapphire, quartz, Irtran
Cells....................................... Gold plated Pyrex or stainless steel
Tubing.................................... FEP Teflon
Fittings................................... 316 stainless steel
Instruction Manual
748175-G
May 2002
350 W with optional case heater
Some configurations may require optional case heater for
temperatures outside 59°F to 95°F (15°C to 35°C). Refer to Section
2-9c, page 2-5.
15.5 in. (39 cm) W
11.8 in. (30 cm) D
Mount in weather protected area.
...................................... ±1% of fullscale per 24 hours
..................................... ±1% of fullscale per 24 hours
(Application dependent)
1
Performance specifications based on ambient temperature shifts of less than 20°F (11°C) per hour.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
1-3
Instruction Manual
748175-G
May 2002
Model 815
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model 815
Instruction Manual
748175-G
May 2002
SECTION 2
INSTALLATION
2-1 UNPACKING
Carefully examine the shipping carton and
contents for signs of damage. Immediately
notify the shipping carrier if the carton or its
contents are damaged. Retain the carton and
packing material until the instrument is
operational
2-2 LOCATION
Locate the analyzer in a weather-protected
location free from vibration. For best results
mount the analyzer near the sample stream to
minimize sample-transport time. Refer to
Installation Drawing 652258.
If equipped with P/N 652271 air purge, refer
to Section 2-9a (page 2-5). The air purge is
designed to provide a corrosion-free or
spectrally-constant internal atmosphere, and
is not intended to provide explosion
hazard protection.
2-3 VOLTAGE REQUIREMENTS
WARNING
Temperature Control Board, Figure 2-3 page
2-3), to the 230 VAC pos ition.
Power consumption is less than 150 watts
without optional case heater; 350 watts with
optional case heater installed.
2-4 ELECTRICAL CONNECTIONS
a. Line Power Connections
Refer to Figure 2-1 (page 2-2) and Figure
2-5 (page 2-6), Installation Drawing
652258 and Pictorial Wiring Diagram
652559.
Route the power cable (customer
supplied 3-wire, minimum 18 AWG)
through the power conduit opening in the
bottom of the instrument.
Connect to power terminal block TB1 as
follows:
HOT/L1 = TB1-1
NEUTRAL/L2 = TB1-2
GROUND = TB1-3 or TB1-4
ELECTRICAL SHOCK HAZARD
For safety and proper performance, this
instrument must be connected to a
properly grounded three-wire source of
electrical power.
Verify that power switch settings are set for
the power available at the site (115 VAC or
220 VAC).
Analyzers are shipped from the factory set for
120 VAC, 50/60 Hz operation. To convert to
220 VAC, 50/60 Hz power, position voltage
select switches S1, S2 (located on Power
Supply Board, Figure 2-2, page 2-3), and S3
(located on the optional Case Heater
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1
b. Recorder Connections
Refer to Figure 2-1 (page 2-2) and Figure
2-5 (page 2-6), Installation Drawing
652258 and Pictorial Wiring Diagram
652559.
Route the cable (customer supplied 2-
wire shielded cable) through the signal
output conduit opening at the bottom of
the enclosure.
Connect to recorder output/current output
terminal block TB2 as follows:
(+)OUTPUT = TB2-1
(- ) OUTPUT = TB2-2
SHIELD (GND) = TB2-3
Instruction Manual
748175-G
May 2002
2-5 SAMPLE CONNECTIONS
Model 815
Zero and span gases are to be connected to
the same inlet fitting as the sample gas.
Refer to Figure 2-1 (page 2-2) and Installation
Drawing 652258. Connect sample gas tubing
to the Model 815 through the 1/4-inch ferrule
type compression fittings located on the
bottom of the enclosure.
2-6 CALIBRATION GAS CONNECTIONS AND
REQUIREMENTS
Refer to Figure 2-1 (page 2-2) and Installation
Drawing 652258.
Linearizer Board
(mounted on farside of Signal Board)
(see Figures 2-6 and 2-7)
Signal Board
(see Figure 2-7)
Power Supply Board
(see Figure 2-2)
All applications require a zero standard gas to
set the baseline point on the digital display or
output signal. Refer to the Calibration and
Data Sheet. Use the background gas as the
zero gas. If a background gas is not specified,
use dry nitrogen for the zero gas.
Span gas concentration is normally between
80% and 100% of the fullscale range the
analyzer will be set on. The background gas
is also indicated on the Calibration and Data
Sheet. If no background gas is specified, use
dry nitrogen.
Motor/Source Assembly
Transformer
(see Figure 6-2)
Sample Cell
Sensor, Case Heater
Temperature Control
(see Figure 2-5)
Reference Cell
Span Potentiometer
Zero/Span
Control Board
MODE Switch
Zero Potentiometer
Current Output Board
(see Figure 2-4)
Signal Output
Case Air Purge Inlet
Power
AC Power Terminal
Block TB1
Sample In
Sample Out
Recorder Output /Current Output
Terminal Block TB2
Fuse
Flame Arrestor
Fitting 1/4 inch Tube Connector
Detector Assembly
(see Figure 6-3)
Case Heater Temperature Control
Assembly
(see Figure 7-8)
Figure 2-1. Model 815 Component Locations
2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model 815
115
115
C18
R39
C21
R20
R18
J
R15
R16
R17
R
+
+
POWER
J11
POWER
J17
S3
+
Instruction Manual
748175-G
May 2002
Set switch windows for voltage required
S2 S1
ADAPTER
1
J16
J12
TEMP
CONTROL
CASE
1
R11
S2 S1
230V
115V
DETECTOR
HEATER
J4
J5
1
K1
4 3 2 1
XFMER
FAN
J2
1
CR4
CR3
CR2
XFMER
C4
+
C2
+
C3
+
C1
S3
SS LUFT
+
+
VR4
VR3
TP1
R9
TP2
TP1 TP2
R12 R13
8
1
7
6
G
I
2
3
45
+
C12
VR2
VR1
I
G
O
I
G
O
I
O
G
O
C6
C8
+
+
C10
+
C11
C5
C7
+
C9
+
R1
R2
R3
R10
R8
R4
R5
R6
R7
AR1
- CR1 +
R9
C13
U1
+
+
R37
R34
R35
R36
C14
C
Q3
E
1
AR4
C19
AR5
CR8
E
A K
10
J14
1
38
1
R25
R29
R26
B
Q2
C
C15
Q1
G
R21
R22
J11
J8
1
+
J15
R24
R23
1
1
J13
Q4
U2
R19
C20
C16
R31
R30
R27
R28
R32
R33
B
CR6
CR7
R14
CR5
J7
Figure 2-2. Power Supply Board
SENSOR J18
400A 880 951E
C2 R10 R11 R7 R8
CR1
R4
C1
C
E
B
Q2
Set switch window for voltage required
Figure 2-3. Case Heater Temperature Control Board
Heater LED (CR5)
R17 R16 R12 CR2
R3
1
AR1
R13
R2R1
Q1
K
G
A
TEMP CONTROL BD
CR3
S3
SUPPLY
R6
C3
R9 R5
1
E
B
Q3
TEST
C
J19
LINE
J5
R15 R14
1 2 1 2 3
T.I.F. HEATER
C4
3 2 1
U2
1
2
3
1
U1
230
115
115
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3
Instruction Manual
748175-G
May 2002
Model 815
2-7 SAMPLE HANDLING SYSTEM
The Model 815 does not contain any filters in
the sample flow system to prevent
contamination of the sample lines or cells.
The sample must be clean and kept above the
dew point to minimize maintenance and to
prolong the life of the components in the
sample flow system. Sample Handling
components and tubing must be constructed
of materials compatible with the sample.
Contact Customer Service Center if an
additional sample handling system is required.
2-8 LEAK TEST
Any leakage must be corrected before
introduction of sample and/or application of
electrical power.
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 instrument explosion-proof
enclosure 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 2-8,
page 2-4.
fullscale at the sample inlet (unless
otherwise specified by the Calibration
and Data Sheet.
2. Seal off sample outlet with a cap while air
or inert gas is flowing into the sample
inlet. If the flowmeter reading drops to
zero, the system is leak free. If the
flowmeter does not drop to zero, a leak in
the system is present and must be
located and sealed before operating the
Model 815.
NOTE:
Whether or not a leak is suspected, the
sample flow system should be leak
checked under pressure before the
analyzer is placed in operation.
3. Refer to the note below, then liberally
cover the outlet plug and all gas
connections with a suitable test liquid
such as SNOOP (PN 837810) to detect
leaks. Apply to all fittings, seals, and
other possible leak sources. Bubbling or
foaming indicates leakage, but the
absence of bubbles does not necessarily
indicate that no leaks exist.
4. If a flow is indicated, a leak is present and
may be in an area that is inaccessible to
SNOOP. Continue leak testing and
tighten all connections until the flow rate
drops to zero.
NOTE:
Do not allow test liquid to contaminate
cells, detector or source windows. Should
this occur, the cells should be cleaned
(Section 6-1, page 6-1.
Internal leaks resulting from failure to
observe these precautions could result in
an explosion causing death, personal
injury or property damage.
The following test is designed for sample
pressure up to 10 psig (69 kPa).
1. Connect air (or other inert gas such as
nitrogen) at 10 psig (69 kPa) to analyzer
via a flow indicator and set flow rate to
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model 815
2-9 OPTIONS
The following options may be ordered as kits
and installed in the field:
Instruction Manual
748175-G
May 2002
Blue Wire
From: Current Output Board TB1-1 (-)
a. Air Purge Kit 652271
WARNING
POSSIBLE EXPLOSION HAZARD
If an air purge is used, the purge inlet
fitting must be equipped with a Flame
Arrestor Assembly (PN 638426) to prevent
propagation of a flame or explosion from
inside the enclosure to the ambient
atmosphere.
All precautions relating to the installation
and operation of this instrument must be
strictly adhered to whether or not the air
purge option is installed. The air purge
option is not intended as protection from
explosion in hazardous areas.
Purging of the enclosure of the explosionproof Model 815 may be recommended in
some applications to provide a corrosion
free internal atmosphere. If the
instrument is to be equipped with an
optional Air Purge Kit, refer to instruction
sheet (748184) supplied in kit for
installation. This kit is designed to
provide a corrosion free or spectrallyconstant internal atmosphere, and is not
intended to provide explosion hazard
protection.
To: Recorder Output/Current Output
Terminal Block TB2-5 (Current Output -)
Orange Wire
From: Current Output Board TB1-2 (+)
To: Recorder Output/Current Output
Terminal Block TB2-4 (Current Output +)
3. Connect the eight conductor flat
cable supplied in kit (PN 652257)
from Current Output Board J2 to
Power Supply Board J9.
4. Refer to Section 3-4 (page 3-9) for 420mA or 0-20mA adjustment
procedure.
c. Case Heater Temperature Control Kit
652270
Refer to Figure 2-1 (page 2-2), Figure 2-2
(page 2-3). Figure 2-3 (page 2-3), Figure
2-5 (page 2-7), Figure 7-8 (page 7-9) and
Pictorial Wiring Diagram 652259.
Installation
1. Mount the Temperature Control
Assembly to the chassis with the 4
screws supplied in the kit.
b. Current Output Kit 652269
Refer to Figure 2-1 (page 2-2), Figure 2-2
(page 2-3), Figure 2-4 (page 2-6), Figure
2-5 (page 2-7), Pictorial Wiring Diagram
652259 and installation Drawing 652258.
Installation
1. Mount the Current Output Board to
the chassis next to the Power Supply
Board using the spacer and hex nut
supplied in the kit.
2. Connect the two-wire cable supplied
in kit (PN 749068) as follows:
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5
2. Attach the sensor (at T.I.F. 2-position
terminal block) to the reference cell
with a tie wrap as shown in Figure 2-1
(page 2-2).
3. Connect the 3-conductor cable
supplied in kit (PN 622903) from
Temperature Control Board J5 to
Power Supply Board J5.
4. Connect the 8-conductor flat cable
supplied in kit (PN 901768) from
Temperature Control Board J11 to
Power Supply Board J11.
Instruction Manual
q
g
748175-G
May 2002
Model 815
Baseline Current
Output Adjust
(0 or 4mA)
Fullscale Current
Output Adjust
(20mA)
Ref Power Supply Board
ZERO
SPAN
C4
+
R7
CR2
R9
CR3
U6
R1
1
1
R2
U2
U1
U3
1 2 3 4
C5
+
+
C9
+
C8
+
C5
+
C7
C1
+
U4
V/I 652442 BD
C2
MA
+ CR1
U5
TB1
-
+
+
C3
I G O
Figure 2-4. Current Output Board
To Power Supply Board
J12
J2
J1
1
O
G
I
To Recorder Output/Current
Output Terminal Block TB2
Ref - Fuse
SPACER
J2
Ref - TB2
Recorder Output/
Current Output
SCREW
uired
4 Re
CURRENT
TB1
NUT
6-32
OUTPUT
BOARD
Ref - TB1
Line Power
J5
J11
SENSOR
See Figure 2-1 for
mountin
location.
TEMPERATURE
CONTROL ASSEMBLY
See Figure 7-8.
Figure 2-5. Installation of Current Output and Temperature Control Options
2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model 815
R5
R6
R9
R2R3R4
R13
R14
Screw, Lock Washer and
R8
R9
R1
R2
R15
6 Pin
Instruction Manual
748175-G
May 2002
d. Linearizer Kit 652268
Refer to Figure 2-1 (page 2-2), Figure 2-6
(page 2-7), Figure 2-7 (page 2-7) and
Pictorial Wiring Di agram 656659
Installation
1. Mount the Linearizer Board to the
Signal Board by inserting the 6-pin
header on the wiring side of the
Header
R5
R6
R7
1
RP1
R10
R11
R12
LINEARIZER BD
Linearizer Board into the 6-position
single-in-line socket on the Signal
board. The through hole on the
Linearizer Board (next to R19) should
be in-line with the swaged threaded
spacer on the Signal Board.
2. Secure the Linearizer Board to the
Signal Board with the screw, lock
washer and flat washer supplied in
the kit.
LIN
1
1
1
1
1
U5
CR2
1 RP2
CR1
R3
R4
R13
R14
U1
U2
U3
U4
TP1
TP2
TP3
TP4
R16
R17
R18
R19
R20
R21
R22
R24
R23
SW1
SW2
CAL
OFF
ON
0
1
2
3
4
5
6
7
8
S
C
Through Hole
R50 R4 R2 R1
C3
ZERO/SPAN
CONTROL
C2
J8
1
R46 C20 C22 R34 R29
POWER SUPPLY
J3
1
J7
1
C1
R7
C7
R60 R11 R10
DISPLAY
U9
R54 R56 R55 R57
C5
U1
R5 CR1C6R6
C4
R8 R9 R16 R14 R15 R21
U2
C9
C8
U4
R13 R18 R19
R49Y1R33 R45 R44
C21
C25 C24 R59 R58
U13
U3
J1
1
OSCILLATOR
Figure 2-6. Linearizer Board
METER RECORDER
1
J6
R20 R23
R31
C10
C23
U11
C12
U5
C16
U8
C14
U7
C18 R42 C18
1
TP1 TP2 TP3 TP4 TP5 TP6 TP7
SW2
R22
C11
SEC 1 2 5 10
C13 R24 R25 R26 R27 R35 R52 R36
C15
R32
R7
R8
R30 R40 R51
G
J2
TEST
O
U6
I
RP1
J4
R10
R11
R12
LINEARIZER BD
R53
1
GAIN PEAK BALANCE
R3
R12
U12
R47
R48
C26
U10
C17 R41 R38
1
R1
U1
1
U2
CR2
1
U3
1 RP2
1
U4
1
CR1
U5
SIGNAL BD
CR2
E1
SW1
SW2
ZERO
R28
R37
SW1
E2
(1)LC
(2)HC
R39
LIN
OFF
ON
0
1
2
3
4
5
6
7
CAL
8
S
C
Flat Washer supplied in
Linearizer Kit
R17
TP1
TP2
R15
R16
R17
R18
R19
R20
R21
R22
R23
TP3
TP4
R24
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7
6-Pin Header located on farside of Linearizer Board
Figure 2-7. Signal Board with Linearizer Board Installed
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