Rosemount CAT 200-Rev C Manuals & Guides

Rosemount Analytical

M

ODEL

C

ONTINUOUS ANALYZER

T

RANSMITTER

O

PERATION AND MAINTENANCE

CAT 200

M

ANUAL

748446-C

OTICE

N

The information contained in this document is subject to change without notice.
This manual is based on the production version of the Model CAT 200 Continuous Analyzer

Transmitter. Hardware and/or software changes may have occurred since this printing.

Teflon® is a registered trademark of E. I. duPont de Nemours and Co., Inc.
SNOOP® is a registered trademark of NUPRO Co.

Manual Part Number 748446-C
March 2001
Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue
Anaheim, California 92807-1802

www.processanalytic.com

C

PREFACE

INTENDED USE STATEMENT..........................................................................P1

SAFETY SUMMARY ..........................................................................................P1

SPECIFICATIONS - GENERAL .........................................................................P4

SPECIFICATIONS – CAT 200 DETECTOR.......................................................P5

CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE............P6

RETURNING PARTS TO THE FACTORY.........................................................P6

TRAINING ......................................................................................................P6

ONTENTS

DOCUMENTATION............................................................................................P6

COMPLIANCES .................................................................................................P7

SECTION 1. INTRODUCTION

1.1 OVERVIEW.................................................................................................1

1.2 TYPICAL APPLICATIONS ..........................................................................2

SECTION 2. DETECTOR METHODOLOGIES

2.1 NON-DISPERSIVE INFRARED (NDIR).......................................................3

2.1.1 Interference Filter Correlation Method...........................................3

2.1.2 Opto-Pneumatic Method................................................................5

2.1.3 Overall NDIR Method.....................................................................6

2.2 PARAMAGNETIC OXYGEN METHOD.......................................................8

2.3 ELECTROCHEMICAL OXYGEN METHOD ................................................10

2.4 THERMAL CONDUCTIVITY METHOD.......................................................12

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

i

ONTENTS

C

SECTION 3. INSTALLATION

3.1 SPECIFICATIONS...................................................................................... 16

3.2 PROCESS AND CALIBRATION GAS CONNECTION ............................... 16

3.2.1 Gas Conditioning........................................................................... 20

3.2.2 Internal Gas Paths......................................................................... 21

3.3 INSTALLATION .......................................................................................... 22

3.3.1 Location ..................................................................................... 22

3.3.2 Limitations..................................................................................... 22

3.3.3 Mounting Options.......................................................................... 22

3.3.4 Vent Lines..................................................................................... 23

3.3.5 Electrical Connections................................................................... 23

3.3.6 Analytical Leak Check................................................................... 28

3.3.6.1 Flow Indicator Method................................................... 28

3.3.6.2 Manometer Method....................................................... 29

3.3.6.3 Troubleshooting Leaks.................................................. 30

SECTION 4. STARTUP AND OPERATION

4.1 STARTUP AND INITIALIZATION ............................................................... 31

4.1.1 Display & Operating Keys..............................................................32

4.1.2 Menu Lines and Softkey Functionality........................................... 33

4.1.3 Common Function Keys................................................................ 34

4.1.4 Entering and Changing Variables.................................................. 35

4.1.5 Starting a Function........................................................................ 35

4.1.6 Main Menu..................................................................................... 36

4.2 BASIC SETUP AND CALIBRATION........................................................... 38

4.2.1 Analyzer Channel Status............................................................... 38

4.2.1.1 Status Details................................................................ 39

4.2.1.2 Acknowledge and Clear Failures................................... 41

4.2.1.3 Current Operation Parameters...................................... 43

4.2.2 Single Component Display............................................................ 44

4.2.3 Multi Component Display .............................................................. 45

4.2.4 Calibration Procedure.................................................................... 46

4.2.4.1 Calibration Status.......................................................... 46

4.2.4.2 Zero Calibration............................................................. 48

4.2.4.3 Span Calibration............................................................ 50

4.2.4.4 Setup Basic Calibration Parameters.............................. 52

4.2.5 Open and Close Valves................................................................. 53

4.3 ANALYZER & I/O, EXPERT CONTROL & SETUP..................................... 55

4.3.1 Analyzer Module Setup................................................................. 56

4.3.1.1 Load Factory Configuration........................................... 57

4.3.1.2 Calibration Parameters.................................................. 58

4.3.1.3 Span Gas Parameter..................................................... 59

4.3.1.4 Calibration Tolerances................................................... 60

ii

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

ONTENTS

C

4.3.1.5 Calibration Procedure Setup..........................................62

4.3.1.6 Timed Controlled Calibration..........................................65

4.3.1.7 Calibration Parameters – Manual Calibration ................67

4.3.1.8 Advanced Calibration Methods......................................68

4.3.1.9 Zero Gas Parameters ....................................................70

4.3.2 Alarm Parameters..........................................................................71

4.3.2.1 Alarm Setup and Control................................................73

4.3.3 Range Parameters.........................................................................74

4.3.3.1 Offset and Span of Range .............................................76

4.3.3.2 Response times (t90)......................................................77

4.3.3.3 Autoranging Control.......................................................78

4.3.4 Cross Interference Compensation.................................................81

4.3.5 Linearization...................................................................................84

4.3.6 Programmable Logic Control (PLC)...............................................88

4.3.6.1 Programming PLC..........................................................89

4.3.6.2 Example for PLC Programming.....................................94

4.3.7 Programmable Calculator..............................................................96

4.3.7.1 Programming the Calculator..........................................97

4.3.7.2 Example for Calculation Programming...........................99

4.3.8 Measurement Display Configuration..............................................100

4.3.9 Acknowledgement of Status Reports.............................................105

4.3.10 Concentration Measurement Parameters....................................107

4.3.11 Concentration Peak Measurement ..............................................108

4.3.12 Differential Measurement.............................................................109

4.3.13 Gasflow Setup .............................................................................111

4.3.14 Pressure Compensation ..............................................................112

4.3.15 Flow Measurement ......................................................................113

4.3.16 Temperature Measurement.........................................................114

4.3.17 Load/Save Analyzer Module Configuration..................................115

4.3.18 Inputs & Outputs (SIO/DIO).........................................................117

4.3.18.1 SIO...............................................................................118

4.3.18.2 DIO...............................................................................124

4.3.18.3 Function Codes............................................................125

4.3.19 Delay and Average......................................................................126

4.3.20 AK-Protocol Communication........................................................128

4.4 SYSTEM CONFIGURATION AND DIAGNOSTICS.....................................129

4.4.1 Diagnostic Menus..........................................................................130

4.4.1.1 Analyzer Module Diagnostics.........................................131

4.4.2 Load/Save Module Configuration...................................................132

4.4.3 Date and Time...............................................................................134

4.4.4 Security Codes...............................................................................135

4.4.5 System Reset.................................................................................137

4.4.6 Memory Usage...............................................................................138

4.5 DISPLAY CONTROLS.................................................................................139

4.6 MEASUREMENT.........................................................................................140

4.7 SHUT DOWN ..............................................................................................140

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

iii

ONTENTS

C

4.8 TEMPERATURE STABILIZATION (OPTION) ............................................ 141

4.8.1 Controller Settings......................................................................... 142

SECTION 5. MAINTENANCE AND SERVICE

5.1 OVERVIEW ................................................................................................ 145

5.1.1 Component Removal..................................................................... 146

5.1.1.1 Analyzer Component Removal...................................... 147

5.1.1.2 Power Supply Assembly Removal................................. 147

5.2 TROUBLESHOOTING GUIDE AND ERROR MESSAGES....................... 148

5.2.1 Instrument not functioning (LCD Display is dark).......................... 148

5.2.2 No or Incorrect Measurement Screen........................................... 148

5.2.3 Display Messages......................................................................... 149

5.2.3.1 Chopper Fail.................................................................. 149

5.2.3.2 Raw Signal too High or Low.......................................... 149

5.2.3.3 Detector Signal Communication Failed......................... 149

5.2.3.4 Light Source.................................................................. 150

5.2.3.5 Detector......................................................................... 150

5.2.3.6 Temperature Measurement........................................... 150

5.2.3.7 Invalid Pressure Measurement...................................... 151

5.2.3.8 External input ................................................................ 151

5.2.4 No or Incorrect Analog Outputs or Digital I/O................................ 152

5.2.5 Calibration not Possible................................................................. 152

5.2.6 Fluctuating or Erroneous Display.................................................. 153

5.2.7 Response Time too Long (t90 time) ............................................... 154

5.3 ANALYZER CONFIGURATION AND ADJUSTMENT ................................ 155

5.3.1 Component Layout........................................................................ 155

5.3.1.1 Circuit Board ICB........................................................... 160

5.3.1.2 Circuit Board PSV.......................................................... 160

5.3.1.3 Circuit Board PIC........................................................... 160

5.3.1.4 Circuit Board ACU......................................................... 161

5.3.2 Analyzer Rear Panel..................................................................... 162

5.3.3 Thermal Conductivity Response Time .......................................... 164

5.4 MAINTENANCE.......................................................................................... 166

5.4.1 Routine and Preventive................................................................. 166

5.4.2 Checking & Cleaning of the Analyzer............................................ 166

5.4.3 Cleaning & Replacement of Photometric Components................. 167

5.4.3.1 Removal of Photometer Assembly................................ 167

5.4.3.2 Light Source Replacement............................................ 167

5.4.3.3 Removal of Analysis Cells............................................. 169

5.4.3.4 Cleaning of Analysis Cells & Windows.......................... 170

5.4.3.5 Reinstalling Analysis Cells............................................. 170

5.4.3.6 Reinstalling Photometer Assembly................................ 171

5.4.3.7 Physical Zeroing............................................................ 171

5.4.4 Replacement of Electrochemical Oxygen Sensor......................... 172

5.4.4.1 Check of the Sensor...................................................... 172

iv

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

ONTENTS

C

5.4.4.2 Removal of the Sensor ..................................................174

5.4.4.3 Replacing the Sensor.....................................................175

5.4.4.4 Reinstalling the Sensor..................................................175

5.4.4.5 Basic Calibration for the Oxygen Sensor.......................175

5.5 ANALYZER SERVICE................................................................................176

5.5.1 Photometer Signal Processing (PCB PSV)....................................176

5.5.1.1 Internal Voltage Supply..................................................177

5.5.1.2 IR Source.......................................................................178

5.5.1.3 Chopper.........................................................................178

5.5.1.4 Unamplified Signal at Detector.......................................179

5.5.1.5 Signal on PCB “PSV”.....................................................180

5.5.2 Physical Zero – Paramagnetic Oxygen..........................................180

5.5.3 Removal of Operator Front Panel..................................................181

5.5.4 Replacement of Buffer Battery.......................................................181

5.5.5 Replacement of Fuses...................................................................182

5.5.6 Test Points for OXS PC Board.......................................................183

5.5.7 Power Supply.................................................................................185

5.5.8 Wiring of DIO with External Devices..............................................186

ENERAL PRECAUTIONS FOR HANDLING

G

ARRANTY

W

IELD SERVICE AND REPAIR FACILITIES

F

TORING HIGH PRESSURE CYLINDERS

& S

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

v

ONTENTS

C

FIGURES

1-1. CAT 200 Continuous Analyzer Transmitter.............................................. 1

2-1. Absorption Bands of Sample Gas and Transmittance of

Interference Filters........................................................................ 4

2-2. Opto-Pneumatic Gas Detector.................................................................. 5

2-3. Overall NDIR Method ................................................................................ 7

2-4. Paramagnetic Oxygen Analysis ................................................................ 9

2-5. Electrochemical Oxygen Sensor............................................................... 10

2-6. Reaction of Galvanic Cell.......................................................................... 11

2-7. Thermal Conductivity Sensor.................................................................... 12

2-8. Response Time vs Flow Rate Dependence.............................................. 13

3-1. Gas Connections...................................................................................... 17

3-2. Piping Diagram (Example)........................................................................ 18

3-3. Outline and Mounting Dimensions............................................................ 19

3-4. Internal Gas Paths (example)................................................................... 21

3-5. Increased Safety Junction Box Terminals................................................. 27

3-6. Leak Test Flow Indicator Method.............................................................. 28

3-7. Leak Test Manometer Method.................................................................. 29

4-1. Temperature Controller............................................................................. 141

5-1. CAT 200 Enclosure Assembly.................................................................. 146

5-2. Analyzer Component Layout (Two IR channels / oxygen measurement,

combined)..................................................................................... 156

5-3. Analyzer Component Layout (Two IR channels / oxygen measurement,

combined)..................................................................................... 157

5-4. Analyzer Component Layout (Two IR channels / oxygen measurement,

combined)..................................................................................... 158

5-5. Analyzer Component Layout (Card Cage and PCB Locations)................ 159

5-6. Plug Locations PCB PIC............................................................................ 160

5-7. Analyzer Rear Panel Layout ..................................................................... 162

5-8. SIO/DIO Pin Assignments (option) (front view of connectors).................. 163

5-9. Pin Assignments DC Power Connector.................................................... 164

5-10. TC Sensor Standard (short) Response Time Setting............................... 165

5-11. TC Sensor Long Response Time Setting................................................. 165

5-12. Analyzer Photometer Assembly ( 2 channel IR, electrochemical oxygen

analyzer, viewed from top)............................................................ 167

5-13. Chopper Housing with IR Light Sources................................................... 168

5-14. Photometer Assembly (1 mm to 10 mm cells).......................................... 169

5-15. Photometer Assembly (30 mm to 200 mm cells)...................................... 169

5-16. PCB OXS Measuring Points.................................................................... 173

5-17. Front Panel Rear View with Oxygen Sensor............................................ 174

5-18. PCB OXS Connections & Measuring Points............................................ 175

5-19. Photometer Block Diagram...................................................................... 176

5-20. PCB VVS................................................................................................. 177

F

IGURES (CONTINUED

vi

)

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

5-21. PCB MOP.................................................................................................178

5-22. Detector Signal.........................................................................................179

5-23. Controller Board ACU...............................................................................181

5-24. Fuses on PCB LEM..................................................................................182

5-25. PCB OXS Test Points ..............................................................................183

5-26. PCB OXS Plug Locations.........................................................................184

5-27. Power Supply Connections......................................................................185

5-28. DIO Inductive Loads.................................................................................186

TABLES

3-1. Analog Output (SIO) Terminal Assignments ...............................................24

3-2. Digital Input & Output (DIO) Terminal Assignments...................................25

3-3. Relay Output Contacts (SIO) Terminal Assignments.................................26

3-4. RS232/RS485 Serial Interface (SIO) Terminal Assignments.....................26

3-5. Power Connections Terminal Assignments................................................26

ONTENTS

C

DRAWINGS (LOCATED IN REAR OF MANUAL)

659922 Assembly Instructions, Basic CAT 200
660210 Installation Drawing, CAT 200
660371 Diagram, Power Input and Ground Circuits

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

vii

ONTENTS

C

NOTES

viii

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

P

REFACE

I

NTENDED USE STATEMENT

The Model CAT 200 Continuous Analyzer Transmitter 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 applications.

SAFETY SUMMARY

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 this
equipment should be thoroughly familiar with and strictly follow the instructions
in this manual. Save these instructions.

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

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

WARNING is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.

CAUTION is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.

NOTE is used to indicate installation, operation, or maintenance information which is
important but not hazard related.

WARNING: ELECTRICAL SHOCK HAZARD

Do not operate without dome and covers secure. Servicing requires access to
live parts which can cause death or serious injury. Refer servicing to qualified
personnel. Operating personnel must not remove instrument covers.

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

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

P1

REFACE

P

WARNING: DEVICE CERTIFICATION(S)

Any addition, substitution, or replacement of components installed on or in this
device, mucst be certified to meet the hazardous area classification that the
device was certified to prior to any such component addition, substitution, or
replacement. In addition, the installation of such devices or devices must meet
the requirements specified and defined by the hazardous area classification of
the unmodified device. Any modifications to the device not meeting these
requirements, will void the product certification(s).

WARNING: POSSIBLE EXPLOSION HAZARD

Do not open instrument when energized.
Ensure that all gas connections are made as labeled and are leak free. Improper

gas connections could result in explosion and death.

WARNING: TOXI C GA S

This unit’s exhaust may contain hydrocarbons and other toxic gases such as
carbon monoxide. Carbon monoxide is highly toxic and can cause headache,
nausea, loss

Avoid inhalation of the exhaust gases at the exhaust fitting.
Connect exhaust outlet to a safe vent using stainless steel or Teflon line. Check

vent line and connections for leakage.
Keep all tube fittings tight to avoid leaks. See Section 3.3.6 for leak test

information.

of consciousness, and death.

DANGER: TOXIC GAS - PURGE

P2

This device may contain explosive, toxic or unhealthy gas components. Before
cleaning or changing parts in the gas paths, purge the gas lines with ambient air
or nitrogen.

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

REFACE

P

WARNING: PARTS INTEGRITY AND UPGRADES

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

Because of the danger of introducing additional hazards, do not perform any
unauthorized modification to this instrument.

Return the instrument to a Rosemount Analyiical Service office for service or
repair to ensure that safety features are maintained.

CAUTION: PRESSURIZED GAS

This unit requires periodic calibration with a known standard gas. It also may
utilizes a pressurized carrier gas, such as helium, hydrogen, or nitrogen. See
General Precautions for Handling and Storing High Pressure Gas Cylinders at
the rear of this manual.

CAUTION: HEAVY WEI GHT

Use two persons or a suitable lifting device to move or carry the instrument.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

P3

REFACE

P

S

PECIFICATIONS

P

OWER

- G

Universal Power Supply 90-264 VAC, 50-60 Hz, ±10% 180 Watts Maximum at Start
Up. Up to 380 Watts with optional case heater.

D

ETECTORS/NUMBER

NDIR, PMD, E02, TC, UV/VIS (one channel only). Up to three channels in one
analyzer.

M

OUNTING

4” or 6” Pipe, Rack, or Wall Mount

A

REA CLASSIFICATION

See Compliances page P7

C

ORROSION PROTECTION OPTION

Instrument grade air is required. Consult factory for requirements

A

MBIENT RANGE

Temperature: -30° to +5° Celsius. (-34° to 122° F)
Relative Humidity: 5% to 95%

ENERAL

I

NPUTS/OUTPUTS

Digital: RS232 serial data
Analog Current Outputs: Up to 8 isolated 4-20 ma, 500 ohms max load
Analog Digital Outputs: Up to 16, 5-30 VDC, max current 500 ma
Analog Digital Inputs: Up to 8, 0-30 VDC, 2.2 ma

I

NSTRUMENT WEIGHT

120 to 150 lbs. (55-70 kg)

P4

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

SPECIFICATIONS – CAT 200 DETECTOR

REFACE

P

D

ETECTION LIMIT

L

INEARITY

Z

ERO DRIFT

S

PAN DRIFT

R

EPEATABILITY

R

ESPONSE TIME

S

AMPLE FLOW RATE

S

AMPLE PRESSURE

I

NFLUENCE OF PRESSURE

Standard

3,4

3,4

3,4

3,4

7

Pres. Comp. Opt.

I

NFLUENCE OF

T

EMPERATURE

On Zero
On Span
On Span

S

ENSOR MATERIALS IN

C

ONTACT WITH SAMPLE

W

ARM-UP TIME

3

3
3

,8

NDIR Ultra Low

2

NDIR/UV/VIS

3,4

≤1%

2

O

Paramagnetic

3,4

≤1%

2

2

Electrochemical

O

≤1%

3,4

Thermal

Conductivity

3,4

≤2%

≤1% ≤1% ≤1% ≤1% ≤1%
≤2%/week
≤1%/week

3,4

3,4

≤2%/week
≤1%/week

3,4

3,4

≤2%/week
≤1%/week

3,4

3,4

≤2%/week
≤1%/week

3,4

3,4

≤1% ≤1% ≤1% ≤1% ≤±2ppm
3s ≤ t90 ≤7s

6

<5-6s 12s 3s ≤ t90 ≤ 20s

6

.2-1.5 l/min .2-1.5 l/min .2-1.5 l/min .2-1.5 l/min .2-1.5 l/min

≤1500 hPa abs Atm ≤1500 hPa abs ≤1500 hPa abs ≤1500 hPa abs

7

≤0.01%/hPa

Anodized Alum
Stainless Steel

15 to 50 Min

≤0.1%/hPa

≤1%

≤5%

≤1%

Optional

≤0.1%/hPa

≤0.01%/hPa

Stainless Steel

6

50 Min 15 to 50 Min 50 Min

≤1%
≤1%
≤1%

≤0.1%/hPa

≤0.01%/hPa

≤1%
≤2%
≤1%

Stainless Steel

Teflon

≤0.1%/hPa

≤0.01%/hPa

≤1%
≤5%
≤1%

Stainless Steel

Stainless Steel

(0-10ppm)

CO

2(0-20ppm)

CO

≤0.2ppm

≤±2%/24-hr
≤±2%/24-hr

≤ 10s

≤0.1%/hPa

≤0.01%/hPa

2

≤1%

2

≤5%

2

≤2%

Gold Plated

15 - 50 Min

4

4

4

6

2

Temperature change not greater than 10k in 1 hour.

3

Related to fullscale, per 10°K.

4

At constant pressure and temperature.

6

Dependent on sensor.

7

Related to measuring value.

8

With optional temperature stabilization.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

P5

REFACE

P

CUSTOMER SERVICE, TECHNICAL ASSIST ANCE AND FIELD 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

RETURNING PARTS TO THE FACTORY

Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call: Model Number, Serial Number, and Purchase Order Number or Sales Order

Number.

Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sender, freight collect.

When returning any product or component that has been exposed to a toxic, corrosive
or other hazardous material or used in such a hazardous environment, the user must
attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification
that the material has been decontaminated, disinfected and/or detoxified.

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

USA

T

RAINING

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.

Phone: [phone]

FAX: [phone]

D

OCUMENTATION

The following Model CAT 200 Continuous Analyzer Transmitter instruction materials
are available. Contact Customer Service or the local representative to order.

748446 Instruction Manual (this document)

P6

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

COMPLIANCES

C

US

This product may carry approvals from several certifying agencies. The certification
marks appear on the product name-rating plate.

AREA CLASSIFICATIONS:

USA

Class I Zone 1
AEx d e m IIB + H2 T4 X

Canada

Ex d e m IIB + H

European Union

ATEX, Category 2, Zone 1, IIB + H2 T4 X

USA/Canada

Certified by Canadian Standards Association, an OSHA
Nationally Recognized Testing Laboratory (NRTL) for
USA and Canada.

2

T4 X

®

REFACE

P

European Union

Conforms with the provisions of the EMC Directive
89/336/EEC, Low Voltage Directive 73/23/EEC,
Potentially Explosive Atmospheres Directive 94/9/EC,
including amendments by the CE marking Directive
93/68/EEC.

EC type Examination Certificate, LCIE 00 ATEX 6009 X.
Rosemount Analytical has satisfied all obligations from

the European Legislation to harmonize the product
requirements in Europe.

Australia/New Zealand

Conforms with Electromagnetic Compatibility – Generic
Emission standard and AS/NZS 4251.1 – 1994 Part 1 –
Residential, commercial, and light industrial.

Complies with the NAMUR RECOMMENDATION,
Electromagnetic Compatibility (EMC) issue 1998.

0081

EEx d e m II B (+H2) T4
LCIE 00 A T EX 6009 X

II 2 G

N96

NAMUR

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

P7

REFACE

P

NOTES

P8

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

I

NTRODUCTION

1

1.1 OVERVIEW

This manual describes the CAT 200 Continuous Analyzer Transmitter.
The CAT 200 is a multi-component, multi-method Continuous Gas Analyzer. Its Class

I, Zone I (IIB) + H2 T2 X approved enclosure makes it suitable for installation in
hazardous environments. The field mountable housing design allows the CAT 200 to
be mounted close to the process instead of in a remote shelter. This feature greatly
reduces installation and utility costs while improving process efficiency.

The CAT 200 can continuously measure 1, 2 or 3 components in a single analyzer
using a combination of Non Dispersive Infrared (NDIR/UV/VIS), Paramagnetic
Oxygen, Thermal Conductivity, Electrochemical sensors. The CAT 200 also features
an optional customized sample-handling module.

The CAT 200 offers advanced menu and diagnostic functionality with the ability to
network multiple analyzers in complex process monitor and control systems. The high
speed microprocessor architecture of the CAT 200 makes it capable of ultra low range
measurements for CO and CO2.

F

IGURE

1-1. CAT 200 C

ONTINUOUS ANALYZER TRANSMITTER

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

1

NTRODUCTION

I

1.2 TYPICAL APPLICATIONS

The CAT 200 Continuous Analyzer Transmitter supports a variety of industry
applications, drawing on more than 40 years of development and process expertise in
sensors, digital signal processing and software technologies. The CAT 200 can satisfy
the most demanding single or multi-component analysis requirements. More than 60
gas components can be measured including:

Carbon Monoxide (CO) Carbon Dioxide (CO2) Methane (CH4)
Hexane (CH equiv.) (C6H14) Water Vapor (H2O) Oxygen (O2)
Hydrogen (H2) Helium (He) Argon (Ar)

Some standard industry applications include:

ETROCHEMICAL REFINERY

P

Light Naphtha Isomerization

H2, CO and CO2 in make-up Hydrogen Gas to Combined Feed
H2 in Scrubber Off Gas to Refinery Fuel Gas Header

Catalytic Reforming

H2 in Recycle Gas from Product Separator
H2 in Net Gas from Net Gas Knockout Drum
H2 in CCR Nitrogen Header
H2 in Surge Hopper Vent

Fluidized Catalytic Cracking

CO and O2 Monitoring of Fluidized Catalytic Cracking Regenerator Gas

Sulfur Recovery Units

Propylene in Feed to Sulfur Recovery Plant

ETROCHEMICAL COMPLEX

P

Ethylene in Primary and Secondary De-Methanizer Overhead
CO2 in Ethane-Ethylene Splitter
Propylene in Splitter Bottoms

MMONIA AND UREA

A

H2, CO and CO2 in Synthesis Gas

TILITIES

U

H2 in Cooling Gas in Turbine Generators
Continuous Emission Monitoring Systems (CEMS)

ET ALS

M

H2 in Endothermic Furnace

LL APPLICATIONS

A

Continuous Emission Monitoring Systems (CEMS)

2

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

D

ETECTOR METHODOLOGIES

2

The CAT 200 can employ up to two of four diff erent measuring methods depending on
the configuration chosen. The methods are: NDIR, Paramagnetic O2, Electrochemical
O2, and Thermal Conductivity.

2.1 NON-DISPERSIVE INFRARED (NDIR)

The non-dispersive infrared method is based on the principle of absorption of infrared
radiation by the sample gas being measured. The gas-specific wavelengths of the
absorption bands characterize the type of gas while the strength of the absorption
gives a measure of the concentration of the gas component being measured.

An optical bench is employed comprising an infrared light source, two analysis cells
(reference and measurement), a chopper wheel to alternate the radiation intensity
between the reference and measurement side, and a photometer detector. The
detector signal thus alternates between concentration dependent and concentration
independent values. The difference between the two is a reliable measure of the
concentration of the absorbing gas component.

Depending on the gas being measured and its concentration, one of two different
measuring methods may be used as follows:

2.1.1 I

NTERFERENCE FILTER CORRELATION METHOD

With the IFC method the analysis cell is alternately illuminated with filtered infrared
concentrated in one of two spectrally separated wavelength ranges. One of these two
wavelength bands is chosen to coincide with an absorption band of the sample gas
and the other is chosen such that none of the gas constituents expected to be
encountered in practice absorbs anywhere within the band.

The spectral transmittance curves of the interference filters used in the CAT 200
analyzer and the spectral absorption of the gases CO and CO2 are shown in Figure 2-

1. It can be seen that the absorption bands of these gases each coincide with the
passbands of one of the interference filters. The forth interference filter, used for
generating a reference signal, has its passband in a spectral region where none of
these gases absorb. Most of the other gases of interest also do not absorb within the
passband of this reference filter.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

3

ETECTOR METHODOLOGIES

D

The signal generation is accomplished with a pyroelectrical (solid-state) detector. The
detector records the incoming infrared radiation. This radiation is reduced by the
absorption of the gas at the corresponding wavelengths. By comparing the
measurement and reference wavelength, an alternating voltage signal is produced.
This signal results from the cooling and heating of the pyroelectric detector material

2

CO

Transmittance (%)

0 15 30 54 60 75 90

CO

Absorption Band

F

IGURE

Transmittance (%)

0 18 36 54 72 90

3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600

2-1. A

BSORPTION BANDS OF SAMPLE GAS AND TRANSMITTANCE OF

I

NTERFERENCE FILTERS

HC CO2 CO

Reference

Wave Length (nm)

4

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

ETECTOR METHODOLOGIES

D

2.1.2 O

PTO-PNEUMATIC METHOD

In the opto-pneumatic method, a thermal radiator generates the infrared radiation
which passes through the chopper wheel. This radiation alternately passes through
the filter cell and reaches the measuring and reference side of the analysis cell with
equal intensity. After passing another filter cell, the radiation reaches the pneumatic
detector.

The pneumatic detector compares and evaluates the radiation from the measuring
and reference sides of the analysis cell and converts them into voltage signals
proportional to their respective intensity.

The pneumatic detector consists of a gas-filled absorption chamber and a
compensation chamber which are connected by a flow channel in which a Microflow
filament sensor is mounted. This is shown in Figure 2-2.

In principle the detector is filled with the infrared active gas to be measured and is only
sensitive to this distinct gas with its characteristic absorption spectrum. The absorption
chamber is sealed with a window which is transparent for infrared radiation. The
window is usually Calcium Fluoride (CaF2).

When the infrared radiation passes through the reference side of the analysis cell into
the detector, no pre-absorption occurs. Thus, the gas inside the absorption chamber is
heated, expands and some of it passes through the flow channel into the
compensation chamber.

F

IGURE

2-2. O

Absorption chamber

Flow channel with
Microflow sensor

PTO-PNEUMATIC GAS DETECTOR

CaF2 Window

Compensation chamber

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

5

ETECTOR METHODOLOGIES

D

When the infrared radiation passes through the open measurement side of the
analysis cell into the detector, a part of it is absorbed depending on the gas
concentration. The gas in the absorption chamber is, therefore, heated less than in the
case of radiation coming from the reference side. Absorption chamber gas becomes
cooler, gas pressure in the absorption chamber is reduced and some gas from the
compensation chamber passes through the flow channel into the absorption chamber.

The flow channel geometry is designed in such a way that it hardly impedes the gas
flow by restriction. Due to the radiation of the chopper wheel, the different radiation
intensities lead to periodically repeated flow pulses within the detector.

The Microflow sensor evaluates these flow pulses and converts them into electrical
pulses which are processed into the corresponding analyzer output.

2.1.3 O

VERALL

NDIR M

ETHOD

In the case of dual-channel analyzers, the broadband emission from two infrared
sources pass through the chopper wheel. In the case of the Interference Filter
Correlation (IFC) method, the infrared radiation then passes through combinations of
interference filters. In the case of the opto-pneumatic method, the infrared radiation
passes through an optical filter depending on the application and need for reduction of
influences. Then the infrared radiation enters the analysis cells from which it is
focused by filter cells onto the corresponding detector. The preamplifier detector
output signal is then converted into the analytical results expressed directly in the
appropriate physical concentration units such as percent volume, ppm, mg/Nm3, etc.
This is shown in Figure 2-3.

6

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

ETECTOR METHODOLOGIES

D

To electronics

Preamplifier

Pneumatic or
pyroelectric detector

(solid-state detector)

window

Filter cell without dividing
wall (IFC) with optical
filters

reference side

measuring side

Preamplifier
Duplex filter disc

VIS / UV

semiconductor detector

window

Filter cell without
dividing wall (IFC)
with optical filters

reference side

measuring side

F

IGURE

Analysis cell

Filter cell with
dividing wall (IR)

Chopper blade

IR source with
reflector

2-3. O

VERALL

NDIR M

ETHOD

Motor

Analysis cell

Filter cell with
dividing wall (UV)

Eddy current drive

VIS / UV source
with reflector

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

7

ETECTOR METHODOLOGIES

D

2.2 PARAMAGNETIC OXYGEN METHOD

The paramagnetic principle refers to the induction of a weak magnetic field, parallel
and proportional to the intensity of a stronger magnetizing field.

The paramagnetic method of determination of oxygen concentration utilizes nitrogen
filled quartz spheres arranged at opposite ends of a bar, the center of which is
suspended by and free to rotate on a thin platinum wire ribbon in a cell. Nitrogen (N2)
is used because it is diamagnetic or repelled by a magnet.

A small mirror that reflects a light beam coming from a light source to a photodetector,
is mounted on the platinum ribbon. A strong permanent magnet specifically shaped to
produce a strong, highly inhomogeneous magnetic field inside the analysis cell, is
mounted outside the wall of the cell.

When oxygen molecules enter the cell, their paramagnetism will cause them to be
drawn towards the region of greatest magnetic field strength. The oxygen molecules
thus exert different forces on the two suspended nitrogen filled quartz spheres,
producing a torque which causes the mirror to rotate away from its equilibrium
position.

The rotated mirror deflects the incident light onto the photodetector creating an
electrical signal which is amplified and fed back to a coil attached to the bar holding
the quartz spheres, forcing the suspended spheres back to the equilibrium position.

The current required to generate the restoring torque to return the quartz bar to its
equilibrium position is a direct m easure of the O2 concentration in the sample gas.

The complete paramagnetic analysis cell consists of an analysis chamber, permanent
magnet, processing electronics, and a temperature sensor. The temperature sensor is
used to control a heat exchanger to warm the measuring gas to about 55 °C. Ref er to
Figure 2-4.

8

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

Light

Source

Amplifier

Photodetector

Platinum Wire

Mirror

ETECTOR METHODOLOGIES

D

Permanent Magnet

Quartz Sphere(s)

Wire Loop

F

IGURE

2-4. P

Display

ARAMAGNETIC OXYGEN ANALYSIS

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

9

ETECTOR METHODOLOGIES

D

2.3 ELECTROCHEMICAL OXYGEN METHOD

The electrochemical method of determining oxygen concentration is based on the
galvanic cell principle shown in Figure 2-5.

Black

Lead Wire (Anode)

Lead Wire (Cathode)

Anode (Lead)

O-Ring

Plastic Disc

Plastic Disk

Acid Electrolyt e

Red

Thermistor

Resistor

Sponge Disc

Cathode (Gold Film)

Teflon Membrane

F

IGURE

2-5. E

LECTROCHEMICAL OXYGEN SENSOR

The electrochemical oxygen sensor incorporates a lead and gold galvanic process
with a lead anode and a gold cathode, using an acid electrolyte.

Oxygen molecules diffuse through a non-porous Teflon membrane into the
electrochemical cell and are reduced at the gold cathode. Water is the byproduct of
this reaction.

On the anode, lead oxide is formed which is transferred into the electrolyte. The lead
anode is continuously regenerated and, therefore, the electrode potential remains
unchanged for a long time. The rate of diffusion and corresponding response time (t90)
of the sensor is dependent on the thickness of the Teflon membrane.

The electric current between the electrodes is proportional to the O2 concentration in
the sample gas being measured. The resultant signal is measured as a voltage across
the resistor and thermistor, the latter of which is used for temperature compensation.
A change in the output voltage (mV) represents oxygen concentration.

10

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

ETECTOR METHODOLOGIES

(

)

(

)

)

)

D

NOTE:
The electrochemical O2 cell requires a minimum internal consumption of

oxygen. Sample gases with an oxygen concentration of less than 2% could
result in a reversible detuning of sensitivity and the output will become
unstable. The recommended practice is to purge the cell with conditioned
ambient air between periods of measurement. If the oxygen concentration is
below 2% for several hours or days, the cell must be regenerated for about one
day with ambient air. Temporary flushing with nitrogen (N2) for less than one
hour (analyzer zeroing) will have no effect on the sensitivity or stability.

Red

Thermistor (5

(-) (+)

Gold Lead

Cathode (2) Anode (1)

O2 + 4 H + 4 e → 2 H2O2 Pb + 2 H

Summary reaction O2 + 2 Pb → 2 PbO

V out

Electrolyte (3)

(ph 6)

Black

Resistor (6

O → 2PbO + 4 H + 4 e

2

F

IGURE

748446-C Rosemount Analytical March 2001

2-6. R

EACTION OF GALVANIC CELL

Model CAT 200 Continuous Analyzer Transmitter

11

ETECTOR METHODOLOGIES

D

2.4 THERMAL CONDUCTIVITY METHOD

Thermal conductivity is an efficient method to measure two-component gas mixtures
such as H2, HE, CO2 and Ar.

Thermal conductivity measuring cells incorporate electrically heated wires with cooling
rates that are influenced by the sample gas in the cell. The cell combines short
response time with minimum interference, which can be effected by variations in the
sample gas flow rate.

The measuring cells consist of an outer ring enclosing a inner cylindrical chamber.
This chamber contains two lateral passages, each equipped with two thermal sensor
devices. One passage is supplied with sample gas and the other is supplied with an
optional reference gas or a closed loop. A variable bypass arrangement permits
adjustments of response time versus flow rate dependence. The cell can be set
between extremes of fast response with relative high dependence on flow rate, or low
response time with least dependence on sample flow rate by rotating the outer section
with respect to the inner section.

Both the cell volume and the mass of its measurement resistor have been minimized
on order to obtain short response time. A nickel resistor is placed between two
superimposed square ceramic plates which form the walls of the measurement cell.
The cell volume is approximately 1 µl. A total of four such cells are integrated to form
the sensor, two of these function as the measurement cells, and the other two function
as the reference cells. The latter may be either sealed off, or connected to a flow of a
reference gas.

F

IGURE

12

2-7. T

Inner chamber

HERMAL CONDUCTIVITY SENSOR

Outer chamber

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

ETECTOR METHODOLOGIES

D

The entire measurement cell is thermostatically controlled to a temperature of up to 55
°C. The four integral temperature sensors are electrically heated to a higher
temperature. Their temperatures, and thus their electrical resistance, are dependent
upon heat losses, which in turn, result from heat absorption in the surrounding gas to
colder chamber walls. For otherwise stable conditions, this heat absorption will be
proportional to the thermal conductivity of the gas present between the sensor and the
chamber wall. Interconnecting the four sensors into a Wheatstone bridge circuit
provides an electronic signal proportional to gas density.

The annular inner chamber is provided with two transverse passages, each of which is
equipped with two temperature sensors. One of these transverse passages is
subjected to a flow of the sample gas, while to other is subjected to a flow of the
reference gas (optional), or is sealed off as a closed loop (standard version). The gas
flow will distribute itself between the transverse passages, or between the annular
grooves on the periphery of the annular chamber.

Timing Constant T

0° 45° 90°

F

IGURE

748446-C Rosemount Analytical March 2001

2-8. R

ESPONSE TIME VS FLOW RATE DEPENDENCE

Flow Dependence

Cell T

∆α

Optimal

Range

Model CAT 200 Continuous Analyzer Transmitter

13

ETECTOR METHODOLOGIES

D

This results in a variable bypass configuration. If the transverse passages are aligned
directly opposite the gas inlet and outlet fittings, there will result the shortest response
times and an enhanced dependence of the analytical signal upon the sample-gas flow
rate.

If the transverse passages are arranged aligned at 90° Angles to these gas fittings,
the heat transport between sample gas and the sensor will be predominantly by
diffusion (i.e. significantly slowed). The dependence of the analytical signal upon
sample gas flow rate will be minimized and the response time extended.

This arrangement has the advantage that any value between the two mentioned
extremes may be set. See Section 5.3.3 for adjustment of the response time versus
flow rate dependence.

The materials in contact with the sample-gas flow rate are aluminum, Viton, stainless
steel and ceramic. This provides for resistance to corrosion which might arise for
some types of aggressive sample gas constitutions.

14

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

I

NSTALLATION

3

+

WARNING: ELECTRICAL SHOCK HAZARD

POSSIBLE EXPLOSION HAZARD

Do not open while energized. Do not operate without dome and covers secure.
Installation requires access to live parts which can cause death or serious
injury.

WARNING: ELECTRICAL SHOCK HAZARD

Installation and servicing of this device requires access to components that
may present electrical shock and/or mechanical hazards. Refer installation and
servicing to qualified service personnel.

WARNING: POSSIBLE EXPLOSION HAZARD

Installation of this device must be made in accordance with all applicable
national and/or local codes. See specific references on installation drawing
located in the rear of this manual.

CAUTION: HIGH PRESSURE GAS CYLINDERS

This unit requires periodic calibration with a known standard gas. It also may
utilizes a pressurized carrier gas, such as helium, hydrogen, or nitrogen. See
General Precautions for Handling and Storing High Pressure Gas Cylinders at
the rear of this manual.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

15

NSTALLATION

I

3.1 SPECIFICATIONS

LECTRICAL POWER

E

See Specifications in Preface

OWER CABLE

P

AC Operation: 16 gauge, minimum.
DC Operation: 12 gauge, minimum.

AS LINES

G

For external gas lines, the use of all new tubing throughout is strongly recommended.
The preferred type is new, refrigeration grade copper tubing, sealed at the ends.
Generally, stainless steel tubing is less desirable as it contains hydrocarbon
contaminants introduced through cleaning. Pre-cleaned and rinsed stainless steel
tubing is available from various supply houses, and is recommended if stainless steel
is desired.

ERVICES

S

All input power, AC or DC as well as input and output digital and analog signals
connect through the Safety Junction Box located above the CAT 100 dome.

3.2 PROCESS AND CALIBRATION GAS CONNECTION

Besides sample gas, the CAT 100 requires other gases for operation. In most cases,
one or more Calibration Standards must be provided. These should be cylinders of
gas which closely resemble the expected sample, both in species and concentrations.
These calibration gases are normally introduced into the system as an input to the
Sample Conditioning Plate Option or sample conditioning may be provided by others.

Each gas cylinder should be equipped with a clean, hydrocarbon free two-stage
regulator with indicating gauges of approximately 0 to 3000 psig (0 to 207 bar) for
cylinder pressure and 0 to 100 psig (0 to 6.7 bar) for delivery pressure. Regulators
should have a metallic as opposed to elastomeric diaphragm, and provide for ¼ inch
compression fitting outlet and should be LOX clean.

Note:
All connections specified in the Installation Drawing, in conjunction with the

Application Data Sheet, should be made.

16

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

1 2 3 4

567

8 9 10 11

NSTALLATION

I

Bottom View

1 – Gas Inlet Ch 1 2 – Gas Outlet Ch 1 3 – Gas Inlet Ch 2* 4 – Gas Outlet Ch 2*
5 – Gas Inlet Ch 3, Reference 1, or Span Gas 1 Inlet* 6 –Gas Outlet Ch 3, Reference 1, or Span Gas 2 Inlet *
7 – Gas Inlet Purge, Reference 2, or Sample Gas Inlet* 8 – Gas Outlet Purge, Reference 2, or Zero Gas Inlet*
9, 10, 11 – Spare

*Option – Purge Gas or Reference Gas

F

IGURE

3-1. G

AS CONNECTIONS

Purge and reference option combination is only available with two channel analyzer.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

17

NSTALLATION

(

)

A

I

An example of a typical gas connection arrangement for a one channel to three
channel series analyzer is shown in Figure 3-2.

Span gas 1

Span gas 2

Sample gas

Zero gas

Solenoid Valves

not supplied

V1

V2

V3

V4

NALYZER

Channel 3

(option)

Throttle and Dust Filter

(not supplied)

Channel 2

(option)

Gas Sampling Pump
(not supplied)

Gas Outlet

Channel 1

Gas Inlet

Flow Meter
(not supplied)

F

IGURE

3-2. P

IPING DIAGRAM (EXAMPLE

)

When the optional auto-calibration solenoid valves are installed, the sample gas is
introduced to connection 9 instead of connection 1 or 3. In this case, the outlet at
connection 5 is used.

An external flow meter may be used (if no internal is available) to adjust the flow rate.
In hazardous areas this must be done in accordance with the legilation. The flow
must be adjusted so that calibration gases and sample gas have the same rate. The
auto calibration solenoid valve option is only available with a two-channel analyzer
with series connection.

18

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

[

]

[

]

[

]

27.00

[

]

[

]

[

]

[

]

[

]

685.8

14.25
362

16.00

406.4

13.00

330.2

A

MOUNTING HOLE
.625 [15.88] DIA

’

NSTALLATION

I

3.00

2.50

[63.5]

D

76.2

2.90

[73.7]

B

F

IGURE

25.50

647.7

.62

[15.7]

1.25

[31.8]

2.25

[57.2]

3-3. O

D. SAMPLE HANDLING PLATE OPTION. SIZE AND

C. ELEVEN GAS CONNECTION PORTS (IF REQUIRED

B. ANALOG AND DIGITAL I/O P ORTS (M16 x 1.5).
A. INCREASED SAFETY JUNCTION BOX.

C

2.00

50.8

1.00

25.4

UTLINE AND MOUNTING DIMENSIONS

ARRANGEMENT SUBJECT TO APPLICATION.

FOR APPLICATION, FLAME ARRESTOR(S)
INSTALLED). SEE FIGURE 3-2.

Note: The Increased Safety Junction Box must be
protedcted by fuse supply which has a breaking
capacity adjusted to the short circuit of the
equipment.

DIMENSIONS

INCH

MM

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

19

NSTALLATION

I

3.2.1 G

AS CONDITIONING

If the CAT 200 is not supplied with the optional Sample Handling Plate, care must be
taken to ensure that the sample gas is properly conditioned for successful operation of
the various detectors.

All gases must be supplied to the analyzer as conditioned gases! W hen the system is
used with corrosive gases, it must be verified that there are no gas components which
may damage the gas path components.

The gas conditioning must meet the following conditions:

• Free of condensable constituents

• Free of dust above 2 µm

• Free of aggressive constituents which may damage the gas paths

• Temperature and pressure in accordance with the specifications

When analyzing vapors, the dewpoint of the sample gas must be at least 10 °C below
the ambient temperature in order to avoid the precipitation of condensate in the gas
paths.

An optional barometric pressure compensation feature can be supplied for the CAT

200. This requires a pressure sensor with a range of 800 – 1,100 hPa. The
concentration values computed by the detectors will then be corrected to eliminate
erroneous measurements due to changes in barometric pressure.

The gas flow rate must be in the range of 0.2 l/min to a maximum of 1.5 l/min. A
constant flow rate of 1 l/min is recommended.

NOTE:
The maximum gas flow rate for paramagnetic oxygen detectors is 1.0 l/min!

20

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

NSTALLATION

CO2/H2O

I

3.2.2 I

NTERNAL GAS PATHS

The possible variations of the internal gas paths are shown in Figure 3-4 for a three
channel analyzer. The variations depend on the configuration chosen. Certain options
may not be available depending on the number of channels and the gas path options
chosen. See specific configuration for analyzer.

In Out

Tubing in series

In OutIn OutIn Out

Tubing in parallel

(limited reference options)

F

IGURE

Tubing in series and

parallel

(special tubing)

ULCO

Special tubing

(External in series)

(Internal in parallel)

3-4. I

NTERNAL GAS PATHS (EXAMPLE

In OutIn Out

ultra low

CO

COhigh

)

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

21

NSTALLATION

I

3.3 INSTALLATION

CAUTION

Do not operate or service this instrument before reading and understanding this
instruction manual and receiving appropriate training.

+

WARNING: ELECTRICAL SHOCK HAZARD

POSSIBLE EXPLOSION HAZARD

Do not open while energized. Do not operate without dome and covers secure.
Installation requires access to live parts which can cause death or serious
injury.

WARNING: HIGH PRESSURE GAS CYLINDERS

This unit requires periodic calibration with a known standard gas. It also may
utilizes a pressurized carrier gas, such as helium, hydrogen, or nitrogen. See
General Precautions for Handling and Storing High Pressure Gas Cylinders at
the rear of this manual.

Refer to the installation drawing supplied with the application data package.

3.3.1 L

3.3.2 L

OCATION

The CAT 200 is designed to be installed in unsheltered environmental locations. It is
recommended that the analyzer be located out of direct sunlight to the extent possible.

The CAT 200 should be installed as near as possible to the sample point, in order to
avoid low response time caused by long sample gas lines.

IMITATIONS

Ambient Temperature: -30° to 50° C (-34° to 122° F)
Relative Humidity: 5% to 95%

3.3.3 M

The CAT 200 can be mounted to either 4-½ or 6-¼ inch diameter pipe stands.
Alternately, the analyzer can be wall or floor mounted.

22

OUNTING OPTIONS

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

NSTALLATION

I

Although the CAT 200 is enclosed in an explosion proof and environmentally sealed
enclosure, it should be protected from direct sunlight. In areas subjected to harsh
winter climates, protection should be provided from rain and snow. A corrugated
awning or other suitable means can be provided to meet these conditions.

See drawing 660210 on the inside of the rear cover for typical pipe mounting method.
Note that the mounting stand is an option.

3.3.4 V

ENT LINES

Connect all vent lines (these are specified on the Application Data Sheet) to an
appropriate header. The header should have a means of being purged when venting
dangerous gases. Insure that there is no back pressure in the vent system as this will
cause variations in the repeatability of the system.

3.3.5 E

LECTRICAL CONNECTIONS

Notes:

1) The enclosure is a NEMA 4X IP 55. All entry locations must be sealed.

2) North American area classification – Class I Zone 1, Group IIB + H2 T4.
Cenelec Category 2 – Zone 1, Group IIB + H2 T4.

3) Readily accessible main power disconnect to be supplied by customer.

4) Electrical installation to be in accordance with National Electrical Code.
(ANSI/NFPA 70) and or other applicable national or local codes.

Connect all required signal cables to the Increased Safety Junction Box. The cable
entry locations are indicated on the inside cover of the junction box. The actual
electrical connections will be specified in the Application Data package. All
connections are not necessary for every application.

All digital inputs and digital outputs are made through the Increased Safety Junction
Box. Cable length for these signals should not exceed 3,000 feet (914 meters), to
avoid excessive capacitance and corresponding signal distortion.

The following connections are made through the Increased Safety Junction Box:

• Electrical Power – ½” conduit

• Analog Outputs – ½” conduit

• Digital Outputs & optional RS232/RS485 – ½” conduit

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

23

NSTALLATION

I

Terminal Description

Top 1 (blk) 4-20 current output 1
Top 2 (brn) 4-20 current output 2
Top 3 (red) mA return for output 1 & 2
Top 4 (org) 4-20 current output 3 (option)
Top 5 (yel) 4-20 current output 4 (option)
Top 6 (grn) mA return for output 3 & 4
Top 7 (blu) 4-20 current output 5 (option)
Top 8 (vio) 4-20 current output 6 (option)
Top 9 (gry) mA return for output 5 & 6
Top 10 (wht) 4-20 current output 7 (option)
Top 11 (wht/blk) 4-20 current output 8 (option)
Top 12 (wht/brn) mA return for output 7 & 8

T

ABLE

3-1. A

NALOG OUTPUT

(SIO) T

ERMINAL ASSIGNMENTS

24

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

Terminal Description

Bottom 1 (blk) Digital output 1
Bottom 2 (brn) Digital output 2
Bottom 3 (red) Digital output 3
Bottom 4 (org) Digital output 4
Bottom 5 (yel) Digital output 5
Bottom 6 ((grn) Digital output 6
Bottom 7 (blu) Digital output 7
Bottom 8 (vio) Digital o utput 8
Bottom 9 (gry) Digital output 9
Bottom 10 (wht) Digital output 10
Bottom 11 (wht/blk) Digital output 11
Bottom 12 (wht/brn) Digital output 12
Bottom 13 (wht/red) Digital output 13

NSTALLATION

I

Bottom 14 (wht/org) Digital output 14
Bottom 15 (wht/yel) Digital output 15
Bottom 16 (wht/grn) Digital input 1
Bottom 17 (wht/blu) Digital input 2
Bottom 18 (wht/vio) Digital input 3
Bottom 19 (wht/gry) Digital input 4
Bottom 20 (blk/red) Digital input 5
Bottom 21 (blk/org) Digital input 6
Bottom 22 (blk/yel) Digital output common 1-8
Bottom 23 (blk/grn) Digital output common 9-15

NOTE:
The loading of the open collector digital outputs is a maximum of 30 VDC and

500 mA.

See Section 5.5.8

T

ABLE

3-2. D

IGITAL INPUT

& O

UTPUT

(DIO) T

ERMINAL ASSIGNMENTS

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

25

NSTALLATION

I

Terminal Description

Top 18 (wht/vio) Relay contact 1
Top 19 (wht/gry) Relay contact 2
Top 20 (wht/red) Relay contact 3
Top 21 (blk/org) Relay contacts common

NOTE:
Non-voltage carrying contacts, maximum 30 V, 1 A, 30 W.

T

ABLE

T

ABLE

T

ABLE

3-3. R

ELAY OUTPUT CONTACTS

Terminal RS232 RS485

Top 13 (wht/red) Ground Ground
Top 14 (wht/org) RxD RxD ­Top 15 (wht/yel) TxD RxD +
Top 16 (wht/grn) Not used TxD +
Top 17 (wht/blu) Not used TxD -

3-4. RS232/RS485 S

Terminal Description

3-5. P

OWER CONNECTIONS TERMINAL ASSIGNMENTS

(SIO) T

ERIAL INTERFACE

ERMINAL ASSIGNMENTS

(SIO) T

1 Hot (line In)
2 Neutral
3 Ground
4 Ground

ERMINAL ASSIGNMENTS

26

Connect AC power through a 10A circuit breaker that is to be located close to the CAT

200. The circuit breaker will provide over current protection as well as a means of
disconnecting the power.

Maximum power requirements will be 180 watts, with most applications requiring less
than this amount.

NOTE:
The optional case heater may increase power requirements to 380 watts.

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

EMI Filter Bottom

124

1 4

NSTALLATION

I

F

IGURE

Power

3-5. I

1

Top

24

NCREASED SAFETY JUNCTION BOX TERMINALS

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

27

NSTALLATION

I

3.3.6 A

NALYTICAL LEAK CHECK

If explosive or hazardous gas samples are being measured with the CAT 200, it is
recommended that gas line f ittings and components be thoroughly leak-checked prior
to initial application of electrical power, bi-monthly intervals thereafter, and after any
maintenance which involves breaking the integrity of the sample containment system.

3.3.6.1 F

LOW INDICATOR METHOD

Supply air or inert gas such as nitrogen, at 10 psig (689 hPa), to the analyzer through
a flow indicator with a range of 0 to 250 cc/min. Install a shut-off valve at the sample
gas outlet. Set the flow rate to 125 cc/min.

CAT 200 Analyzer

Inlet Outlet

Flow
Meter

F

IGURE

(69 kPa)

3-6. L

N2

10 psig

EAK TEST

- F

LOW INDICATOR METHOD

Close the outlet shut-off valve and notice that the flow reading drops to zero. If the
flow reading does not drop to zero, the system is leaking and must be corrected
before the introduction of any flammable sample gas or application of power.

Gas Outlet

28

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

NSTALLATION

I

3.3.6.2 M

ANOMETER METHOD

Install a water-filled U-tube manometer at the sample gas outlet. Install a shut-off
valve at the sample gas inlet. Admit air or inert gas to the inlet shut-off valve until the
analyzer is pressurized to approximately 50 hPa. The water column will be about 500
mm.

CAT 200 Analyzer

Inlet Outlet

Overpressure
Approx. 50 hPa

N2

Water

F

IGURE

3-7. L

EAK TEST

- M

ANOMETER METHOD

Close the inlet shut-off valve and, following a brief period for pressure equilibrium,
verify that the height of the water column does not drop over a period of about 5
minutes. If the water column height drops, the system is leaking and must be
corrected before the introduction of any flammable sample gas or application of
power.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

29

NSTALLATION

I

3.3.6.3 T

ROUBLESHOOTING LEAKS

Liberally cover all fittings, seals, and other possible sources of leakage with a suitable
leak test liquid such as SNOOP (part 837801). Bubbling or foaming indicates leakage.
Checking for bubbles will locate most leaks but could miss some, as some areas are
inaccessible to the application of SNOOP. For positive assurance that system is leak
free, perform one of the tests above.

NOTE:

Refer to Specification in Preface for maximum pressure limitations.
For differential measurement, the leak check must be performed for the

measurement and reference side separately.
For analyzers with parallel gas paths, the leak check must be performed for

each gas path separately.

30

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

S

TARTUP AND OPERATION

4

4.1 STARTUP AND INITIALIZATION

Once the CAT 200 has been correctly assembled and installed in accordance with the
instructions in Section 3.3, “Installation,” the analyzer is ready for operation.

Before operating the system, verify that the Leak Checks have been performed and
that the sample handling unit is performing correctly.

Apply power to the system and verify that sample gas is flowing.

NOTE:
A warm-up time of from 15 to 50 minutes is required depending on the installed

detector(s).

After switching on the CAT 200, the analyzer will begin its booting procedure which is
apparent on the LCD screen. The first part of the initialization procedure is a self
check of the software and analyzer components. Various displays will show the status
of the initialization including revision notes, “Initializing network interface,” “Searching
for nodes,” and “Calculating bindings.”

© 1999 FISHER-ROSEMOUNT Analytical

MLT Control-Module Rev. 3.3.4/P008

Language: P009/01/00

Initializing Network

Initializing network interface

LCDReset Abort

Pressing the F1 key during initializing will reset the LCD brightness and contrast to
factory settings (See Section 4.5). Pressing the F3 key will abort the network
initializing, aborting any connection to other analyzers. In that case, only the menus of
the local analyzer will be available.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

31

TARTUP AND OPERATION

S

At the end of the initializing routine the “single component” screen will display as
shown on the next page. This screen is the access to all other channels, menus and
submenus. The actual display may differ from that shown depending on any custom
configuration as described in Sections 4.3.8 and 4.5.

4.1.1 D

ISPLAY

PERATING KEYS

& O

The LCD screen shows all measurement values of the analyzer, status values and all
user menu instructions. Operation is performed with five function keys, four arrow
(cursor) keys and the enter key. The function of each key varies depending on the
installed analyzer module, any auxiliary modules installed, and the individual menu
displayed.

In case of power failure, all user defined specific module parameters are saved by a
battery powered memory.

MLT/CH1/R1

37.30 ppm CH4

0.00 Range 1 50.00

Failures:
Maintenance-Requests:
Temperature:
Operation:

Display Status… Main… Channel BasicCal

0.0 100.0

Cursor
Keys

32

Function Keys

Enter Key

The Function Keys, also called softkeys, are assigned values depending on the
menu or screen being displayed. The legend is displayed above the keys.

The Enter Key is used to confirm a previously entered variable value, to start a
selected function or to go to a submenu selected at a menu line as opposed to the
Function Keys. As an alternate to using the Enter Key to start a function, the → key
can be used.

The Cursor Keys (↑ or ↓) are used to move up or down the lines within a menu or to
increment and decrement number variables.

The Cursor Keys (← or →) are used to move backwards or forwards between the
pages of a menu or to select numeric digits for adjustment.

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.1.2 M

ENU LINES AND SOFTKEY FUNCTIONALITY

Menu lines can be selected with the ↑ key or the ↓ key. The selected line is displayed
as white lettering on a black background (highlighted). Menus can contain four
different types of lines:

Menu Line – A line ending with three dots (…) indicates that it leads to a submenu.
The submenu can be activated by pressing the ↵ key or the → key when the line is
highlighted.

Function Line – A line ending with an exclamation point (!) indicates that it will start a
function. The function can be activated by pressing the ↵ key or the → key when the
line is highlighted.

Variable Line – A line ending with a colon (:) indicates that it displays a module
variable parameter. Some parameters can be changed and some parameters display
only a status and cannot be changed. Paramters that cannot be changed will be
displayed below a line within the menu.

Text Line – A line without punctuation marks only displays information.
Tag Line – At the top of each menu page is the tag line of the current channel in the

format – MLT / CHannel # / Range #. To the right of the Tag is the value of the
indicated channel.

Tag Line

Menu Line (highlighted)

Function Lines

Variable Lines

Variables below this

line cannot be changed

Tag Line Value

MLT/CH1/R1 37.50 ppm

-- Basic Controls and Setup --

Calibration procedure status…

Start zero calibration procedure!
Start span calibration procedure!
Check calibration deviation: Enabled

Range number: 1
Span gas: 100 ppm
Range upper limit: 100 ppm

Operation status: Ready

Measure Status… Channel Back… Valves…

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

33

TARTUP AND OPERATION

S

The Function Keys (Softkeys) can sometimes be assigned as Functions (exclamation
point) or Submenus (three dots) as shown below.

MLT/CH1/R1 37.50 ppm

-- Calibration Procedure Status --

Procedure status: Ready
Maximum remaining procedure time: 0 s
Valve position: Samplegas
Concentration in span gas units: 37.50 ppm

Last zero calibration: Success
Last span calibration: Success
Last zero calibration was: 13:32:06 July 27
Last span calibration was: 13: 37: 23 Augus t 11
Successful zero+span calibrated ranges: 1+2+3+4

Measure Cancel ! Back… More…

-------------------- Results ------------------------

4.1.3 C

Function Softkey

OMMON FUNCTION KEYS

Menu Softkeys

Display – Change form the single component display to the multi-component display.
F1 in the single component display.

Measure – Change from menus and submenus to the single component display of the
selected channel. F1.

Status – Change to the menu “Analyzer Channel Status” which displays the most
important parameters and information about the status of the current channel or
module. F2 if available. (See Section 4.2.1)

Main – Change from single component display to the main menu. F3 in the single
component display. (See Section 4.1.6)

Channel – Scrolls through the channels in the same menu. In the main menu and the
single component display menu it moves between the channels of the connected
analyzers and analyzer modules. IN the submenus it moves only between the
channels of the current analyzer or analyzer module. F3 if available, F4 in the single
component display.

34

Lock – Changes to the main menu and locks all three operation levels, if a security
code is enabled in the system configuration (See Section 4.4.4). F4 in the main
menu.

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

BasicCal – Change from the single component display to the menu “Analyzer module

calibration.” F5 in the single component display. (See Section 4.3.1.7)
MFG Data – Change from the main menu to the menu “Module Manufacturing Data”

which displays further submenus with information about the control module and
analyzer module, such as address of the manufacturer, serial number of the modules
and software and hardware versions. F5 in the main menu. (See Section 4.1.6 “F5”)

More – Changes to an additional menu page of the current menu. F5 if available.

4.1.4 E

NTERING AND CHANGING VARIABLES

1. Select the variable line desired to be changed using the ↑ key or the ↓ key. The
selected line will be highlighted white on black.

2. Press the ↵ key and the parameter will be selected for modification.

3. Use the ↑ key or the ↓ key change the value, scroll among the available variables
or change the value of a selected digit or character.

4. Use the ← key or the → key to select digits within a number. For some variable
the quantity of digits or characters can be changed.

5. Press the ↵ key again to confirm the new value.

4.1.5 S

TARTING A FUNCTION

Pressing the ↵ key or the → key while a function line is highlighted will bring up a
confirmation menu as shown below.

MLT/CH1/R1 37.50 ppm

-- Confirmation Required --

Do you really want to do this ??

Press “Yes” or “Back…”

Yes Back…

Pressing the F2 key will start the function immediat e ly.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

35

TARTUP AND OPERATION

S

Pressing the F4 key will return to the previous menu page.
The confirmation prompt can be disabled in the “Measurement Display Configuration”

menu under the expert configuration level. See Section 4.3.8. In such case, each
function will start directly after the f unction menu line is selected and no confirmation
will be required.

4.1.6 M

AIN MENU

Pressing the F3 key (Main…) or the → key while in any single component display will
bring up the Main Menu. From the Main menu it is possible to change all operating
values of the analyzer to set up and control the parameters of measurement,
calibration and data transfer.

From the Main menu, the F5 key (MFG Data) will access several submenus showing
the manufacturing and version data of the analyzer.

ELECTIONS FROM THE MAIN MENU

S

MLT/CH1/R1 37.50 ppm

-- Main Menu --

Analyzer basic controls (calibration) & setup…

Analyzer and I/O, expert controls & setup…
System configuration and diagnostics…
Display cont r o l s…
Time & Date: 14:01:45 29 July 1999

System tag: Fisher-Rosemount

Measure Status… Channel Lock… MFG Data

:

See Section 4.2
See Section 4.3.1
See Section 4.4
See Section 4.5
See Section 4.4.3

36

F1 – Changes to the single component display of the current channel. See Section

4.1.

F2 – Changes to the “Analyzer Channel Status” menu of the current channel. See

Section 4.2.1.

F3 – Scrolls through all channels of the connected analyzers and analyzer modules.

See channel tag.

F4 – Locks any operating level by security code. See Section 4.4.4.
F5 – Changes to “Module Manufacturing Data” menu as follows:

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

Selections from the “Module Manufacturing Data” menu (F5):

TARTUP AND OPERATION

S

MLT/CH1/R1 90.00 ppm

-- Module Manufacturing Data --

Control module data…

Analyzer module data…

Measure <<< Back… >>>

MLT/CH1/R1 90.00 ppm

(C) Copyright Fisher-Rosemount GmbH & Co, 1999

Manufactured by:

Fisher-Rosemount GmbH &

Industriestrasse 1

D-63594 Hasselroth / Germany

Tel. [phone]

FAX [phone]

Measure Back… More…

MLT/CH1/R1 90.00 ppm

-- Analyzer Module Version Information --

Serial number: d941029
Manufacturing date: 29.07.1999

Hardware revision: ACU02 R: 3.3.2, Final D:Jul 2
Software revision: 3.3.4 / P008 /Ch5

Revision date: Nov 2 1999
Revision time: 11:03:13

MLT/CH1/R1 90.00 ppm

(C) Copyright Fisher-Rosemount GmbH & Co, 1999

Manufactured by:

Fisher-Rosemount GmbH & Co

Industriestrasse 1

D-63594 Hasselroth / Germany

Tel. [phone]

FAX [phone]

Measure Or… Back… More…

MLT/CH1/R1 90.00 ppm

-- Control Module Version Information --

Serial number: d9410129
Manufacturing date: 29.07.1999

Hardware revision: ACU02 R: 3.3.2, Final D:Jul 2
Software revision: 3.3.4 / P008

Revision date: Nov 2 1999
Revision time: 11:00:05

Phrase dictionary version: P009/01/00
Language: English

Measure Back…

MLT/CH1/R1 90.00 ppm

Copyright Fisher-Rosemount Analytical Inc., 1998

Manufactured by:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, CA 92807-1802 /USA

Tel: [phone]

FAX: [phone]

Measure Back… More…

MLT/CH1/R1 90.00 ppm

-- Hardware Configuration --

Measurement system: PSV-System
RAM-memory: 745376 Bytes
Local SIO module installed: Enabled

Serial interface adapter: RS-232
Heater installed: No
Local DIO module installed: 2
Sensor system revision:
Sensor system serial number:

Measure Channel Back…

748446-C Rosemount Analytical March 2001

Measure Back…

Model CAT 200 Continuous Analyzer Transmitter

37

TARTUP AND OPERATION

S

4.2 BASIC SETUP AND CALIBRATION

The following sections describe the basic control of the analyzer, the viewing of
channel parameters and the calibration of channels. Examples of stepping through the
menus are shown in schematic form so that the user can become familiar with the
operation, keeping in mind that displays and menu choices may be different
depending on actual analyzer configuration and any customization of the menus.

4.2.1 A

NALYZER CHANNEL STATUS

MLT/CH1/R1

37.50 ppm CH4

0.00 Range: 1 50.00

Failures: No
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Analyzer Channel Status --

Status details…

Current operation parameters…
General status: Normal
Hours of operation: 164
Operation status: Ready
Events: No
Alarms: No
Failures: No
Maintenance requests: No
Function control/Service: No

Measure RawMeas Channel Back… More…

F1 F2 F3 F4 F5

↵↵↵↵

Notes:

↵↵↵↵

If necessary, from the Main
menu press F1 “Measure.”

Change to the “Analyzer
Channel Status” menu.

Press F2

From the “Analyzer Channel
Status” menu additional
submenus are available for
“Status details..." and “Current
operational parameters…” as
described in Sections 4.2.1.1
and 4.2.1.3.

The F2 key changes to the
“Primary raw measurements”
submenu and then the F5 key
changes to the “Secondary
raw measurements” submenu.

38

MLT/CH1/R1

37.50 ppm CH4

0.00 Range: 1 50.00

Failures: No
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

The F5 key changes to the
“Special Functions” submenu.

Change back to the single
component display.

Press F1

↵↵↵↵

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.2.1.1 S

MLT/CH1/R1

Failures: No
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel Calib…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

Status details…

Current operation parameters…
General status: Normal
Hours of operation: 164
Operation status: Ready
Events: No
Alarms: No
Failures: No
Maintenance requests: No
Function control/Service: No

Measure RawMeas Channel Back… More…

TATUS DETAILS

37.50 ppm CH4

0.00 Range: 1 50.00

-- Analyzer Channel Status --

Change to the “Analyzer
Channel Status” menu.

Press F2

↵↵↵↵

Change to the “Status details”
submenu.

Press Enter or →→→→ key

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Status Details--

Failures…

Maintenance requests…
Functions controls…
Alarms…
Events…

Acknowledge and clear failures!
Acknowledge and clear maintenance requests!
Acknowledge and clear function controls!

Measure Back…

F1 F2 F3 F4 F5

↵↵↵↵

↵↵↵↵

Note:

Change to the “List of Possible
Failure (1/2)” men u

Press Enter or →→→→ key

In order to change to other
available status details, select
the menu line with the
keys and then press the

↑↑↑↑

or

↵↵↵↵

key.

↓↓↓↓

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

39

TARTUP AND OPERATION

S

MLT/CH1/R1 37.50 ppm

-- List of Possible Failures (1/2) --

One or more failures: No
Configuration replaced by factory setting: No
Chopper fail: No
Raw signal overflow: No
Detector signal communication failed: No
Source: No
Detector: No
Heater control: No
Temperature measurement: No
Invalid pressure measurement: No

Measure Back… More…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- List of Possible Failures (1/2) --

External input: No

Change to the second menu
page.

Press F5

↵↵↵↵

Measure Back

F1 F2 F3 F4 F5

MLT/CH1/R1

37.50 ppm CH4

0.00 Range: 1 50.00

Failures: No
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel Calib…

F1 F2 F3 F4 F5

↵↵↵↵

Change back to the single
component display.

Press F1

↵↵↵↵

40

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.2.1.2 A

MLT/CH1/R1

Failures: Yes
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel Calib…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

Status details…

Current operation parameters…
General status: Normal
Hours of operation: 164
Operation status: Ready
Events: No
Alarms: No
Failures: No
Maintenance requests: No
Function control/Service: No

Measure RawMeas Channel Back… More…

F1 F2 F3 F4 F5

CKNOWLEDGE AND CLEAR FAILURES

37.50 ppm CH4

0.00 Range: 1 50.00

-- Analyzer Channel Status --

This function is used after the
reasons for reported failures
have been corrected. Then the
menu “List of Possible Failures,”
will be ready for new reports.

Use of this function is only
possible if it is enabled in the
“Acknowledgement of Status

↵↵↵↵

Reports” with the line
“Acknowledgement allowed in
status menu:” answered Yes.

Change to the “Analyzer
Channel Status” menu.

Press F2

Change to the “Status details”

↵↵↵↵

submenu.

MLT/CH1/R1 37.50 ppm

-- Status Details--

Failures…

Maintenance requests…
Functions controls…
Alarms…
Events…

Acknowledge and clear failures!
Acknowledge and clear maintenance requests!
Acknowledge and clear function controls!

Measure Back…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Status Details--

Failures…
Maintenance requests…
Functions controls…
Alarms…
Events…

Acknowledge and clear failures!

Acknowledge and clear maintenance requests!
Acknowledge and clear function controls!

Measure Back…

Press Enter or →→→→ key

Change to the line
“Acknowledge and clear
Failures”

Press ↑↑↑↑ or ↓↓↓↓ key

↵↵↵↵

Start the function
Press Enter or →→→→ key

F1 F2 F3 F4 F5

748446-C Rosemount Analytical March 2001

↵↵↵↵

Model CAT 200 Continuous Analyzer Transmitter

41

TARTUP AND OPERATION

S

MLT/CH1/R1 37.50 ppm

-- Confirmation Required --

Do you really want to do this ??

Press “Yes” or “Back…”

Yes Back…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

- SUCCESS -

- The selected function has been started/executed ­(Wait a moment…)

Confirm the command.
Press F2 to start the function

immediately.
Press F4 to cancel the

command and return to the
“Status Details” menu.

↵↵↵↵

Confirmation message appears.
The message will be displayed

momentarily after the start of the
function. Then the display will
change automatically to the
“Status Details” menu.

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Status Details--

Failures…

Maintenance requests…
Functions controls…
Alarms…
Events…

Acknowledge and clear failures!
Acknowledge and clear maintenance requests!
Acknowledge and clear function controls!

Measure Back…

F1 F2 F3 F4 F5

MLT/CH1/R1

37.50 ppm CH4

0.00 Range: 1 50.00

Failures: Yes
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

↵↵↵↵

Change back to the single
component display.

Press F1

↵↵↵↵

The other functions in the
“Status Details” menu can be
acknowledged and cleared in
the same way as just described.
These are:

Acknowledge and clear
maintenance requests!

42

Display Status… Main… Channel Calib…

F1 F2 F3 F4 F5

Acknowledge and clear function

↵↵↵↵

controls!

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.2.1.3 C

MLT/CH1/R1

Failures: Yes
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel Calib…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

Status details…

Current operation parameters…

General status: Normal
Hours of operation: 164
Operation status: Ready
Events: No
Alarms: No
Failures: No
Maintenance requests: No
Function control/Service: No

Measure RawMeas Channel Back… More…

URRENT OPERATION PARAMETERS

37.50 ppm CH4

0.00 Range: 1 50.00

-- Analyzer Channel Status --

This function is used to view and
control various operational
parameters of the current
channel and controlled
calibrations.

From the single channel display:
Change to the “Analyzer

↵↵↵↵

Channel Status” menu.
Press F2
Move the cursor to the “Current

operation parameters…” line.
Press Enter

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

Remote control via serial port (AK): Enabled
Range and calibration control: Manual
Range: 1
Range upper limit: 50.00 ppm
Span gas concentration: 50.00 ppm
T90-time: 2.00 s
Hours of operation: 164
Last re-start occurred: 8:40:35 June 22, 1999
Actual zero gas concentration: 0.00 ppm

Auto-start procedures…

Measure Channel Back…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

Position in the auto-start list: 1

Channel tag: MLT/CH!/CO
Procedure type: SPAN
Interval mode: Each Day
Start time: 00:00:00
Start date: -

Time & Date: 16:03:25 July 28, 1999

Measure Back…

-- Analyzer Operation Settings --

-- Auto-Start Procedures --

↵↵↵↵

Change to the “Auto Start
Procedures” menu.

Press Enter

↵↵↵↵

In this menu the three time
controlled calibrations can be
changed.

Press F1 to return to the single
component display of the
current channel.

F1 F2 F3 F4 F5

748446-C Rosemount Analytical March 2001

↵↵↵↵

Model CAT 200 Continuous Analyzer Transmitter

43

TARTUP AND OPERATION

S

4.2.2 S

INGLE COMPONENT DISPLAY

Use the following steps to change the channel of the single component display:

MLT/CH1/R1

2.50 % CO2

0 Range: 1 5.00

Temperature: 25.0 C 0.0 100.0
Maintenance-Requests: No
Any_Alarms: No
Operation: Ready

From the single channel display:

Press F4
Example:

Changing from CO2 (channel 1)

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

MLT/CH1/R1

95.00 ppm CO

↵↵↵↵

to CO (channel 2)

Continue pressing F4 to display
the desired channel depending
on the analyzer configuration,

0 Range: 2 250

Temperature: 25.0 C 0.0 100.0
Maintenance-Requests: No
Any_Alarms: No
Operation: Ready

ultimately returning to the first
channel.

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

MLT/CH1/R1

2.50 % CO2

0 Range: 1 5.00

Temperature: 25.0 C 0.0 100.0
Maintenance-Requests: No
Any_Alarms: No
Operation: Ready

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

↵↵↵↵

Single component display of the
starting channel.

↵↵↵↵

44

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.2.3 M

ULTI COMPONENT DISPLAY

To change from the single component display to the multi component display:

MLT/CH1/R1

2.50 % CO2

0 Range: 1 5.00

Temperature: 25.0 C 0.0 100.0
Maintenance-Requests: No
Any_Alarms: No
Operation: Ready

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

↵↵↵↵

From the single channel display:
Press F1

Note:
Changing from the multi
component display can be
done from each single
component display.

Each bargraph shows the start

2.00

95.00

150.0

MLT13/CH1
MLT13/CH2

MLT13/CH3

0.00 [2] 5.00

0.00 [2] 250.00

0.00 [2] F.S. 150.00

and end of the range for the
respective channel. The number
in parentheses indicates the
number of the selected range for
that channel. (F.S. = fullscale)

Select Status… Tags Off LCDReset

F1 F2 F3 F4 F5

2.00

> 95.00

150.0

Select Status… Tags Off LCDReset

F1 F2 F3 F4 F5

MLT/CH1/R1

95.00 ppm CO

0 Range: 2 250

Temperature: 25.0 C 0.0 100.0
Maintenance-Requests: No
Any_Alarms: No
Operation: Ready

MLT13/CH1
MLT13/CH2

MLT13/CH3

0.00 [2] 5.00

0.00 [2] 250.00

0.00 [2] F.S. 150.00

Use the F3 key to turn the tags
on or off.

↵↵↵↵

To select a single channel in the
multi channel display, enable
the select symbol (>) by
pressing the F1 key or the ↓↓↓↓
key.

↵↵↵↵

Then use the ↓↓↓↓ or ↑↑↑↑ key to
select the line for the desired
channel. For example, to display
CO (channel 2).

When the desired channel is
marked, select it for single
component display by pressing
the F1 key.

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

748446-C Rosemount Analytical March 2001

↵↵↵↵

Model CAT 200 Continuous Analyzer Transmitter

45

TARTUP AND OPERATION

S

4.2.4 C

ALIBRATION PROCEDURE

To insure correct analyzer measurement, zeroing and spanning should be performed
at least once per week. The span calibration must be performed after the zeroing.

For analyzers with Ultra Low CO measurement, the calibration should be performed
on a daily basis.

For either manual or automatic calibration, the required test gases must be fed to the
analyzer through the respective gas inlets with a no-back-pressure flow rate of about
1 l/min, the same as the sample gas.

NOTE:
After switching on the analyzer, wait at least approximately 15 to 50 minutes

(depending on installed detectors) for instrument warm up before feeding gas to
the analyzer.

NOTE:
If the optional internal or external solenoid valves are installed, the valves are

automatically actuated by digital outputs for the respective function.

4.2.4.1 C

MLT/CH1/R1

Failures: Yes
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel Calib…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

Calibration Procedure Status…

Start zero calibration procedure !
Start span calibration procedure !
Check calibration deviation: Enabled

Range number: 1
Span gas: 46.00 ppm
Range upper limit: 50.00 ppm

Operation status: Ready

Measure Status… Channel Back… Valves…

F1 F2 F3 F4 F5

ALIBRATION STATUS

37.50 ppm CH4

0.00 Range: 1 50.00

-- Basic Controls and Setup --

From the single channel display
change to the “Basic Controls
and Setup” menu “BasicCal”:

Press F5

↵↵↵↵

Change to the “Calibration
Procedure Status” menu:

Press Enter
Use the F5 key to change to a

submenu to close all valves or
setup each valve separately with
zero gas, span gas, sample gas,
or test gas. See Section 4.2.5.

↵↵↵↵

46

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

MLT/CH1/R1 37.50 ppm

-- Calibration Procedure Status --

Procedure Status: Ready
Maximum remai ning procedure time: 0 s
Valve position: Samplegas
Concentration in span gas units: 37.50 ppm

--------------------------- Results --------------------------­Last zero calibration: Success
Last span calibration: Success
Last zero was: 13:32:06 July 27, 1999
Last span was: 13:37:23 July 29, 1999
Successful zero+span calibrated ranges:: 1=2=3=4

Measure Cancel ! Back… More…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Calibration Deviations --

Deviation from zero: 0.34 ppm
Sum of zero deviations: 4.41 ppm

Deviation from span: 0.82 ppm
Sum of span deviations: 7.57 ppm

Measure Channel Back…

Change to the “Calibrations
Deviations” menu:

Press F5

↵↵↵↵

Notes:
A basic calibration procedure

will reset the deviations to

0.00 (see Section 4.3.1.8,
“Start basic calibration
procedure !”)

Use the F3 key to check
calibration deviations of other
available channels.

F1 F2 F3 F4 F5

MLT/CH1/R1

37.50 ppm CH4

0.00 Range: 1 50.00

Failures: Yes
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel Calib…

F1 F2 F3 F4 F5

↵↵↵↵

Use the F4 key to return to the
“Calibration Procedure
Status” menu.

To return to the single
component display:

Press F1

↵↵↵↵

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

47

TARTUP AND OPERATION

S

4.2.4.2 Z

ERO CALIBRATION

For zeroing, the analyzer has to be flushed with nitrogen (N2) or an adequate zero gas
such as synthetic or conditioned air. Air cannot be used for oxygen zeroing.

From the single channel display

MLT/CH1/R1

37.50 ppm CH4

0.00 Range: 1 50.00

Failures: Yes
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

change to the “Basic Controls
and Setup” menu “BasicCal”:

Press F5

Note:
Before starting zero
calibration, make sure that

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

↵↵↵↵

zero gas is available.
Note:

All measurement ranges of
the same channel are zeroed

MLT/CH1/R1 37.50 ppm

-- Basic Controls and Setup --

Calibration Procedure Status…

Start zero calibration procedure !

Start span calibration procedure !
Check calibration deviation: Enabled

Range number: 1
Span gas: 46.00 ppm
Range upper limit: 50.00 ppm

Operation status: Ready

Measure Status… Channel Back… Valves…

at the same time.

Change to the “Start zero
calibration !” menu:

Press the ↓↓↓↓ key once
Press Enter or →→→→

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Confirmation Required --

Do you really want to do this ??

Press “Yes” or “Back…”

Yes Back…

F1 F2 F3 F4 F5

↵↵↵↵

Confirm the command to start
the zero calibration:

Press F2
Or
Press F4 to cancel the

procedure

↵↵↵↵

Note:
The display of this message
depends on the setup in the
expert controls and setup.
See Section 4.3.8.

48

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

MLT/CH1/R1 37.50 ppm

-- Calibration Procedure Status --

Procedure Status: Purging1-Wait
Maximum remai ning procedure time: 8 s
Valve position: Zerogas
Concentration in span gas units: 37.50 ppm

----------------------------- Results ----------------------------­Last zero calibration: Success
Last span calibration: Success
Last zero calibration was: 13:32:06 July 27, 1999
Last span calibration was: 13:38:46 July 28, 1999
Successful zero+span calibrated ranges: 1+2+3+4

Measure Cancel ! Back… More…

F1 F2 F3 F4 F5

MLT/CH1/R1 3.13 ppm

-- Calibration Procedure Status --

Procedure Status: Zeroing-Wait
Maximum remaining procedure time: 97 s
Valve position: Zerogas
Concentration in span gas units: 3.13 ppm

----------------------------- Results ----------------------------­Last zero calibration: Success
Last span calibration: Success
Last zero calibration was: 13:32:06 July 27, 1999
Last span calibration was: 13:38:46 July 28, 1999
Successful zero+span calibrated ranges: 1+2+3+4

Measure Cancel ! Back… More…

F1 F2 F3 F4 F5

The following illustrations show
the displays after starting the
zero calibration procedure.

Note:
The calibration procedure can
be cancelled at any time by
pressing the F2 key.

↵↵↵↵

Zeroing:
1st: Purging1-Wait

The purging time depends on
the parameters entered for
purge time. See Section 4.3.1.4.
The purge time must be long
enough to get a stable gas
concentration before calibration.

Zeroing:
2nd: Zeroing-Wait

The procedure time depends on

↵↵↵↵

parameters entered for stability
time and averaging time. See
Section 4.3.1.5.

MLT/CH1/R1 37.50 ppm

-- Calibration Procedure Status --

Procedure Status: Purging2-Wait
Maximum remai ning procedure time: 8 s
Valve position: Zerogas
Concentration in span gas units: 7.50 ppm

----------------------------- Results ----------------------------­Last zero calibration: Success
Last span calibration: Success
Last zero calibration was: 13:32:06 July 27, 1999
Last span calibration was: 13:38:46 July 28, 1999
Successful zero+span calibrated ranges: 1+2+3+4

Measure Cancel ! Back… More…

F1 F2 F3 F4 F5

MLT/CH1/R1 0.00 ppm

-- Calibration Procedure Status --

Procedure Status: Ready
Maximum remai ning procedure time: 0 s
Valve position: Samplegas
Concentration in span gas units: 0.00 ppm

----------------------------- Results ----------------------------­Last zero calibration: Success
Last span calibration: Success
Last zero calibration was: 13:32:06 July 27, 1999
Last span calibration was: 13:38:46 July 28, 1999
Successful zero+span calibrated ranges: 1+2+3+4

Measure Cancel ! Back… More…

F1 F2 F3 F4 F5

Zeroing:
3rd: Purging2-Wait

The purging time depends on
the parameters entered for
purge time. See Section 4.3.1.5.
The purge time must be long
enough to get a stable gas
concentration before calibration.

↵↵↵↵

Zeroing:
Completed

To return to single component
display:

Press F1
To change back to “Analyzer

Module Calibration” press F4.
To change to “Calibration

Deviations” press F5.

↵↵↵↵

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

49

TARTUP AND OPERATION

S

4.2.4.3 S

PAN CALIBRATION

The span gas concentration should be in the range or 80% to 110% of the fullscale
range of the analyzer. If lower span gas concentrations are used, the measuring
accuracy for sample gas concentrations higher than the span gas concentration will be
compromised. Spanning for oxygen measurement can be done using ambient air as
span gas, if the oxygen concentration is known and constant.

To calibrate analyzers with Ultra Low CO measurement internal H2O channel (0­3%vol, used for cross compensation), use water vapor saturated N2 as a span gas,
according to the according to the saturation characteristics. Purge N2 through a gas­bubbler bottle, filled with distilled water and at a slightly higher ambient temperature as
necessary. Connect a second vessel into a kyrostat (to hold the ambient temperature
constant) in series to get a defined dew point.

From the single channel display

MLT/CH1/R1

37.50 ppm CH4

0.00 Range: 1 50.00

Failures: Yes
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

↵↵↵↵

change to the “Basic Controls
and Setup” menu “BasicCal”:

Press F5

Note:
Before starting span
calibration, make sure that
span gas is available.

Note:
Normally all measurement
ranges of the same channel

MLT/CH1/R1 37.50 ppm

-- Basic Controls and Setup --

Calibration Procedure Status…
Start zero calibration procedure !

Start span calibration procedure !

Check calibration deviation: Enabled
Range number: 1

Span gas: 46.00 ppm
Range upper limit: 50.00 ppm

Operation status: Ready

Measure Status… Channel Back… Valves…

F1 F2 F3 F4 F5

↵↵↵↵

are spanned at the same time.
To calibrate separately,
change the parameters. See
Section 4.3.1.2.

Change to the “Start span
calibration !” menu:

Press the ↓↓↓↓ key twice
Press Enter or →→→→
Confirm the command to start

the span calibration:

MLT/CH1/R1 37.50 ppm

Press F2
or

-- Confirmation Required --

Press F4 to cancel the
procedure

50

Do you really want to do this ??

Press “Yes” or “Back…”

Yes Back…

F1 F2 F3 F4 F5

Note:
The display of this message
depends on the setup in the

↵↵↵↵

expert controls and setup.
See Section 4.3.8.

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

MLT/CH1/R1 37.50 ppm

-- Calibration Procedure Status --

Procedure Status: Purging1-Wait
Maximum remai ning procedure time: 4 s
Valve position: Spangas-1
Concentration in span gas units: 37.50 ppm

----------------------------- Results ----------------------------­Last zero calibration: Success
Last span calibration: Success
Last zero calibration was: 09:21:34 July 27, 1999
Last span calibration was: 13:37:23 July 27, 1999
Successful zero+span calibrated ranges: 1+2+3+4

Measure Cancel ! Back… More…

F1 F2 F3 F4 F5

MLT/CH1/R1 43.57 ppm

-- Calibration Procedure Status --

Procedure Status: Spanning-Wait
Maximum remai ning procedure time: 108 s
Valve position: Spangas-1
Concentration in span gas units: 43.57 ppm

----------------------------- Results ----------------------------­Last zero calibration: Success
Last span calibration: Success
Last zero calibration was: 09:21:34 July 27, 1999
Last span calibration was: 13:37:23 July 27, 1999
Successful zero+span calibrated ranges: 1+2+3+4

Measure Cancel ! Back… More…

F1 F2 F3 F4 F5

The following illustrations show
the displays after starting the
span calibration procedure.

Note:
The calibration procedure can
be cancelled at any time by
pressing the F2 key.

↵↵↵↵

Spanning:
1st: Purging1-Wait

The purging time depends on
the parameters entered for
purge time. See Section 4.3.1.2.
The purge time must be long
enough to get a stable gas
concentration before calibration.

Spanning:
2nd: Spanning-Wait

The procedure time depends on

↵↵↵↵

parameters entered for stability
time and averaging time. See
Section 4.3.1.2.

MLT/CH1/R1 37.50 ppm

-- Calibration Procedure Status --

Procedure Status: Purging2-Wait
Maximum remai ning procedure time: 4 s
Valve position: Samplegas
Concentration in span gas units: 17.50 ppm

----------------------------- Results ----------------------------­Last zero calibration: Success
Last span calibration: Success
Last zero calibration was: 09:21:34 July 27, 1999
Last span calibration was: 13:37:23 July 27, 1999
Successful zero+span calibrated ranges: 1+2+3+4

Measure Cancel ! Back… More…

F1 F2 F3 F4 F5

MLT/CH1/R1 50.00 ppm

-- Calibration Procedure Status --

Procedure Status: Ready
Maximum remai ning procedure time: 0 s
Valve position: Samplegas
Concentration in span gas units: 50.00 ppm

----------------------------- Results ----------------------------­Last zero calibration: Success
Last span calibration: Success
Last zero calibration was: 09:21:34 July 27, 1999
Last span calibration was: 13:37:23 July 27, 1999
Successful zero+span calibrated ranges: 1+2+3+4

Measure Cancel ! Back… More…

F1 F2 F3 F4 F5

Spanning:
3rd: Purging2-Wait

The purging time depends on
the parameters entered for
purge time. See Section 4.3.1.2.
The purge time must be long
enough to get a stable gas
concentration before calibration.

↵↵↵↵

Spanning:
Completed

To return to single component
display:

Press F1
To change back to “Analyzer

Module Calibration” press F4.
To change to “Calibration

Deviations” press F5.

↵↵↵↵

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

51

TARTUP AND OPERATION

S

4.2.4.4 S

ETUP BASIC CALIBRATION PARAMETERS

The basic setup parameters for calibration can be changed from the “Basic Controls
and Setup” menu as described below:

MLT/CH1/R1

37.50 ppm CH4

From the single channel display
change to the “Basic Controls
and Setup” menu “BasicCal”:

0.00 Range: 1 50.00

Failures: Yes
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

↵↵↵↵

Press F5

Change to the desired

MLT/CH1/R1 37.50 ppm

-- Basic Controls and Setup --

Calibration Procedure Status…

Start zero calibration procedure !
Start span calibration procedure !
Check calibration deviation: Enabled

Range number: 1
Span gas: 46.00 ppm
Range upper limit: 50.00 ppm

Operation status: Ready

Measure Status… Channel Back… Valves…

parameter as described below:

Press the ↓↓↓↓ or ↑↑↑↑key to highlight
the desired line.

Press Enter or →→→→

F1 F2 F3 F4 F5

HECK CALIBRATION DEVIATION

C

:

↵↵↵↵

Enables and disables the stability and tolerance check during calibration. Press Enter
on the line and use the ←←←← or →→→→ keys to toggle the value.

ANGE NUMBER

R

:

Select the desired range number from 1 to 4 for viewing or setting the span gas and
range upper limit. Or define another range. Press Enter on the line and use the ←←←← or
→→→→ keys to toggle through the value.

PAN GAS

S

:

Set the span gas value of the calibration gas. Press Enter on the line and use the ←←←←
or →→→→ keys to change the value. Values outside the linearity limit of the analyzer will not
be accepted.

ANGE UPPER LIMIT

R

:

Set the range upper limit. . Press Enter on the line and use the ←←←← or →→→→ keys to
change the value. Values outside the linearity limit of the analyzer will not be
accepted.

52

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

Press the Enter ↵↵↵↵ key to accept new values or return to previous parameters with the
F2 key.

4.2.5 O

PEN AND CLOSE VALVES

The following procedure shows how to manually turn on valves to start gas flowing for
zero, span, sample and test gas:

MLT/CH1/R1

37.50 ppm CH4

0.00 Range: 1 50.00

From the single channel display
change to the “Basic Controls
and Setup” menu “BasicCal”:

Failures: Yes
Maintenance-Requests: No
Temperature: 20.0 C 0.0 100.0
Operation: Ready

Display Status… Main… Channel BasicCal

F1 F2 F3 F4 F5

↵↵↵↵

Press F5

Note:
Before starting gas flow,
make sure that gas is
available.

MLT/CH1/R1 37.50 ppm

-- Basic Controls and Setup --

Calibration Procedure Status…

Start zero calibration procedure !
Start span calibration procedure !
Check calibration deviation: Enabled

Range number: 1
Span gas: 46.00 ppm
Range upper limit: 50.00 ppm

Operation status: Ready

Measure Status… Channel Back… Valves…

Change to the “Set Gas Valves”
menu:

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Set Gas Valves --

Flow zero gas !

Flow span gas !
Flow sample gas !
Flow test gas !

Close all valves !

Valve position: Samplegas
Operation status: Ready

Measure Status… Channel Back…

F1 F2 F3 F4 F5

748446-C Rosemount Analytical March 2001

↵↵↵↵

Press F5

Start the flow of zero gas:
Press Enter ↵↵↵↵ or →→→→

↵↵↵↵

Model CAT 200 Continuous Analyzer Transmitter

53

TARTUP AND OPERATION

S

MLT/CH1/R1 37.50 ppm

-- Confirmation Required --

Do you really want to do this ??

Press “Yes” or “Back…”

Yes Back…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

- SUCCESS -

- The selected function has been started/executed -

(Wait a moment…)

Confirm the command.
Press F2 to start the function

immediately.
Press the F4 key to cancel the

command and return to the “Set
Gas Valves” menu.

The display of this message

↵↵↵↵

depends on the setup in the
expert controls and setup (See
Section 4.3.8).

Confirmation message appears.
The message will be displayed

momentarily after the start of the
function. Then the display will
change automatically to the “Set
Gas Valves” menu.

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Set Gas Valves --

Flow zero gas !

Flow span gas !
Flow sample gas !
Flow test gas !

Close all valves !

Valve position: Samplegas
Operation status: Ready

Measure Status… Channel Back…

F1 F2 F3 F4 F5

↵↵↵↵

Additional options:

• Start the flow of span gas,
sample gas or test gas.

• Close all valves.

• F3 – Change to another

available channel to execute

↵↵↵↵

gas flow.

• F4 – Go back to “Basic
Controls and Setup” menu to
start zeroing or spanning.

• F1 – Return to single
component display.

54

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.3 ANALYZER & I/O, EXPERT CONTROL & SETUP

Expert control configuration provides access to set up parameters for the
measurement and calibration on the CAT 200 as well as the configuration of the I/O
modules. The applicable parts of these menus and configuration parameters will
depend on the included options of the CAT 200. The following summarizes the top
level structure of these menus:

Main Menu

Expert Module Configuration

Analyzer module controls…
I/O module controls…
Analyzer module setup…
I/O module setup…

MLT/CH1/R1 37.50 ppm

-- Main Menu --

Analyzer basic control (calibration) & setup…

Analyzer and I/O, expert controls & setup…

System configuration and diagnostics
Display controls…
Time & Date: 14:01:45 29 July 1999

System tag: Fisher-Rosemount

Measure Status… Channel Lock… MFG Data

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Expert Module Configuration --

Analyzer module controls…

I/O module controls…
Analyzer module setup…

I/O module setup…

From the Main Menu use the ↓↓↓↓
or ↑↑↑↑ keys to highlight the line
“Analyzer and I/O, expert
controls & setup”

Press Enter ↵↵↵↵ or →→→→

↵↵↵↵

Measure Channel Back…

F1 F2 F3 F4 F5

748446-C Rosemount Analytical March 2001

↵↵↵↵

Model CAT 200 Continuous Analyzer Transmitter

55

TARTUP AND OPERATION

S

4.3.1 A

NALYZER MODULE SETUP

The “Analyzer Module Setup and Controls” menu and its various submenus can be
accessed from the Main Menu as follows:

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

MLT/CH1/R1 37.50 ppm

-- Analyzer Module Setup and Controls (1/3) --

Calibration parameters…

Alarm parameters…
Range Parameters…
Cross interference compensation…
Linearization…
Programmable logic control (PLC)…
Programmable calculator…
Measurement display configuration…
Acknowledgement of status reports…
Concentration measurement parameters…

Measure ManData Channel Back… More…

F1 F2 F3 F4 F5

↵↵↵↵

Change to the desired submenu
using the ↑↑↑↑ and ↓↓↓↓ keys and then
press Enter ↵↵↵↵ or →→→→.

Press F5 to access the next
menu page.

MLT/CH1/R1 37.50 ppm

-- Analyzer Module Setup and Controls (2/3) --

Peak measurement…

Differential measurement…
Gasflow setup…
Pressure compensation…
Flow measurement…
Temperature measurement…
Loading/saving configuration parameters…
Inputs and outputs…
Delay and average…
Special functions…

Measure Channel Back… More…

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Analyzer Module Setup and Controls (3/3) --

Ak-protocol communication…

Measure Back…

↵↵↵↵

56

F1 F2 F3 F4 F5

↵↵↵↵

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.3.1.1 L

OAD FACTORY CONFIGURATION

To delete the user defined RAM configuration parameters and load the factory default
settings for the Flash-EPROM configuration parameters from of the analyzer, perform
the following.

Note:
This function is irreversible after starting and confirmation. The user defined

parameters will be deleted and cannot be recovered!

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

MLT/CH1/R1 37.50 ppm

-- Analyzer Module Setup and Controls (1/3) --

Calibration parameters…

Alarm parameters…
Range Parameters…
Cross interference compensation…
Linearization…
Programmable logic control (PLC)…
Programmable calculator…
Measurement display configuration…
Acknowledgement of status reports…
Concentration measurement parameters…

Measure ManData Channel Back… More…

Press F2 to access the
ManData (Manufacturing Data)
page.

F1 F2 F3 F4 F5

MLT/CH1/R1 37.50 ppm

-- Load Factory Configuration --

↵↵↵↵

Press the Enter ↵↵↵↵ or →→→→ key.
If asked to Confirm, press the

F2 (Yes) key.

- BE CAREFUL with this function -

Replace current configuration with factory settings !

Or
Press the F4 key to cancel the

Measure Back…

F1 F2 F3 F4 F5

↵↵↵↵

operation.

Other key actions:
F1-Measure: Change to the single component display of the current channel. See

Section 4.2.2

F3-Channel: Change to other available channels.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

57

TARTUP AND OPERATION

S

4.3.1.2 C

ALIBRATION PARAMETERS

Several submenus are available under the menu “Calibration Parameters” to allow
setting of the zero and span gas calibration parameters and the start the different
calibration methods.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Calibration parameters…

MLT/CH1/R1 37.50 ppm

-- Calibration Parameters --

Span gases…

Tolerances…
Calibration procedure setup…
Time controlled calibration…
Calibration…
Advanced calibration methods…
Zero gases…

Range and calibration control: Manual

Measure Channel Back…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Change to the submenu or select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Change the variable parameter with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.
The variable parameter “Range and calibration control:” is for the autoranging of the

current channel. This can also be setup from the “Range parameters” menu where
additional description of the function can be found. See Section 4.3.3.

Other key actions:

F1-Measure: Change to the single component display of the current channel.
F3-Channel: Change to other available channels.
F4-Back…: Return to the last menu page.

58

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.3.1.3 S

PAN GAS PARAMETER

This menu is used to set the default value for each range of the current channel, that
actual span gas concentration and the desired span gas unit. The concentration of
each range should be in the range of 70% to 110% of the maximum range value.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Calibration parameters…

Span gases…

MLT/CH1/R1 37.50 ppm

-- Span Gas Definition --

Actual span gas concentration: 250.0 ppm

Spangas range –1: 50.0 ppm
Spangas range –2: 250.0 ppm
Spangas range –3: 2500 ppm
Spangas range –4: 10000 ppm

Span gas unit: ppm
“ppm” -> “mg/Nm3” conversion factor: 1.250

Concentration in span gas units: 37.50 ppm

Measure Back…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Change the variable parameter with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.

Note:
The “ppm” -> “mg/Nm3” conversion factor can be setup in the “General

Concentration Measurement Setup” menu. See Section 4.3.1.0.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

59

TARTUP AND OPERATION

S

4.3.1.4 C

ALIBRATION TOLERANCES

This menu is used to set the tolerances for the stability calibration and maximum
calibration deviation for the current channel. These checks can also be disabled.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Calibration parameters…

Tolerances…

MLT/CH1/R1 37.50 ppm

-- Tolerances --

Max. zero calibration deviation: 30.00 %

Max. span calibration deviation: 20.00 %
Check calibration deviation: Disabled
Stability tolerance – range 1: 10.00 %
Stability tolerance – range 2: 10.00 %
Stability tolerance – range 3: 10.00 %
Stability tolerance – range 4: 10.00 %

Last zero calibration: Success
Last span calibration: Success

Measure Channel Back…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Change the variable parameter with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.
Press F3 to change to the parameters of the other channels.

Max. zero(span) calibration deviation:

The deviation between two zero or span gas concentrations will be determined during
the stability time of the calibration procedure (See Section 4.3.1.5). The deviation
tolerance is expressed as the percent of the current range. Calibration will only be
possible within this tolerance.

If a small deviation tolerance is chosen, the calculated value may be out of range
during the entire calibration time and the calibration will time out. If a large deviation
tolerance is chosen, the ca libration may lack stability. The value is u sually set to 10%
or 20%. The default values are 30% for zero calibration and 20% for span calibration.

60

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

Stability tolerance:

These values define the stability control during the calibration procedure in fullscale
percent. If the deviation is outside this tolerance during the first stability time is
complete, a second stability process will start automatically. This will be repeated as
long as the reading is outside the tolerance limit up until the maximum procedure time.
The default value is 10%.

Check deviation:

When Enabled, the stability and tolerance checking during the calibration procedure
will be based on the values of the tolerances.

When Disabled, the calibration is performed without any stability and tolerance
checking and any calibration will be accepted.

Example:

End of range: 1000 ppm
Max. calibration deviation: 20% (equivalent to 200 ppm)
Desired value: 990 ppm
Display: 720 ppm
Deviation: 250 ppm (more than 200 ppm!)
Result: m ax. calibration process will time out and

calibration will be canceled.

Possible solutions:

Double the max. calibration deviation settings or disable the “Check deviation”
parameter in which case any calibratio n will be accepted.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

61

TARTUP AND OPERATION

S

4.3.1.5 C

ALIBRATION PROCEDURE SETUP

This menu is used to set up the parameters for the calibration process of the zeroing
and spanning of the current channel. Press the F3 key to set the other channels.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Calibration parameters…

Calibration procedure setup…

MLT/CH1/R1 37.50 ppm

-- Calibration procedure setup --

Purge time: 10 s

Procedure times-out after: 120 s
Analog output during calibration: Tracking
Span ranges: Together

Valve position: Samplegas

Stability time: 30 s
Averaging time: 5 s

Measure Channel Back…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Change the variable parameter with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.
Press F3 to change to the parameters of the other channels.
The measurement should be stable before zeroing and spanning. Therefore, the

analyzer cell should be purged with enough zero or span gas before calibration
readings begin. Then after the purge time, the stability time begins. During the stability
time the average over two signals will be calculat ed. The averaging time de termines
the time difference between these two signals.

62

If the deviation of the two values is less than the allowed maximum calibration
deviation (See Section 4.3.1.4) the calibration will begin. If not, the stability control
starts again until a stable measurement is attained unless the time out value is reach
wherein the process stops without attaining a calibration.

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

g

S

The following diagram shows the process of the stability controlled zero and span gas
calibration:

Averaging

Ti

Concentration

Start Zero

Calibration

Purge Stability Stability Stability Stability Time
Time Time Time Time Time

Start Span
Calibration

Note:
The stability time and averaging time are factory settings and cannot be

changed by the user. For other values, consult with the factory.
Analog output during calibration:

This function allows the analog output and the limits of the local SIO to be held during
calibration.

Tracking: The analog output follows the calibration zero and span values during the
calibration process.

Holding: The analog output is held to the last value before calibration starts and
resumes at the sample gas value after calibration. This can be used when limits are
applied to the analog output that calibration would trip.

Sample Gas Zeroing Spanning Sample Gas

Analog Output
Tracking

Analog Output
Holdin

Note:
The previous chart only shows the basic concept of the analog output. During

actual calibration the purge time will also be relevant. Therefore, if the purge

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

63

TARTUP AND OPERATION

S

time for the sample gas will run first, followed which the holding function will be
switched on.

Span ranges:

Together: All measurement ranges of the same channel will be calibrated together.
This is the usual calibration mode.

Separately: Each measurement range will calibrate separately.
Valve position: options

Samplegas Zerogas Purgegas Testgas
Spangas-1 Spangas-2 Spangas-3 Spangas-4
Linearizer Spangas AllClosed ---­Other-Proc. Basic-Status

64

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.3.1.6 T

IMED CONTROLLED CALIBRATION

This menu is used to set up the parameters for the starting time of the zero and span
calibration of the current channel. Press the F3 key to set the other channels.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Calibration parameters…

Time controlled calibration…

MLT/CH1/R1 37.50 ppm

-- Time Control --

Zero calibration – Day of week: Never

- Hour: 0

- Minute: 0

Span calibration – Day of week: Never

- Hour: 0

- Minute: 0

Zero+Span calibration – Day of week Never

- Hour: 0

- Minute: 0

Measure Channel Back… ShowList…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Change the variable parameter with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.
Press F3 to change to the parameters of the other channels.
For day of week the options are: Monday – Sunday, Each day, Never
For hour the options are: 1 – 23
For minute the options are 1 – 59
Time controlled calibration is only possible if the span gas comes from the optional

solenoid valves or an external sample conditioning system. If these are not provided,
all time control “Day of week” settings should be set to “Never.”

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

65

TARTUP AND OPERATION

S

A zero gas calibration should be performed before starting a span gas calibration.
Therefore, the starting time of the zero gas calibration should be before the starting
time of the span gas calibration. Selecting the “Zero+Span calibration” option will
automatically run the zero before the span.

Press the F5 key (ShowList…) to see the “Auto-Start procedures” menu.

MLT/CH1/R1 37.50 ppm

-- Auto-Start Procedures --

Position in auto-start list: 1

Erase current position from list !
Erase all positions from list !

Channel tag: ­Procedure type: ­Interval mode: Never
Start time: ­Start date: -

Measure Back…

F1 F2 F3 F4 F5

↵↵↵↵

If time controlled calibration has been disabled (Never) in the previous “Time Control”
menu, it is necessary to reset the memory to avoid further calibrations. This is
accomplished by the function “Erase current position from list !” which will reset the
memory for the selected position in the “Position in auto-start list:” variable. The three
potions are:

Position 1: Zero calibration
Position 2: Span calibration
Position 3: Zero+Span calibration

Starting the “Erase all positions from the list !” function will delete the time control
setups for all three type of calibrations.

The last five lines in the menu show the parameters of the selected position line.

66

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.3.1.7 C

ALIBRATION PARAMETERS

ANUAL CALIBRATION

– M

This menu allows the manual starting of a zero or span calibration for all
measurement ranges of the current channel.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Calibration parameters…

Calibration…

MLT/CH1/R1 37.50 ppm

-- Basic Controls and Setup --

Calibration procedure status…

Start zero calibration procedure !
Start span calibration procedure !
Check calibration deviation: Enabled

Range number: 1
Span gas: 100.00 ppm
Range upper limit: 100.00 ppm

Operational status: Ready

Measure Status… Channel Back… Valves…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓
keys.

Start the function with the
Enter ↵↵↵↵ or →→→→ keys or cancel
and go back with the F4 or ←←←←
key.

If asked, confirm with the F2 key

MLT/CH1/R1 37.50 ppm

-- Set Gas Valves --

Flow zero gas !

Flow span gas !
Flow sample gas !
Flow test gas !

Close all valves !

Valve position: Samplegas
Operational status: Ready

Measure Status… Channel Back…

F1 F2 F3 F4 F5

↵↵↵↵

or cancel and go back with the
F4 or ←←←← key.

Press F5 to change to the “Set
Gas Valves” menu.

Establish the gas flow of the
current channel as desired.

Before starting a calibration make sure the signal is stable.
The “Analyzer Module Calibration” menu and its submenus is the same as that under

“Basic Controls.” The calibration and gas flow procedures are the same as found in
Sections 4.2.4.2, 4.2.4.3, and 4.2.5.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

67

TARTUP AND OPERATION

S

In order to calibrate or set up the other channels, change to the channel with the F3
key. To start the zero or span calibration for all channels simultaneously, access the
“Advanced Calibration Methods” menu in Section 4.3.1.8.

To span calibrate the measurement ranges separately, set the Separately” parameter
in the “Span ranges” line of the “Calibration Procedure Setup” menu described in
Section 4.3.1.5.

The F2 key shows the “Analyzer Channel Status” menu as described in detail in
Section 4.2.1. From that menu and its submenus can be found that status of the
current channel for:

Failures Maintenance requests Function controls

Alarms Events Hours of operation

And the operational settings of the current channel:

Range settings Response time (t90)

The results of the last calibrations are shown in the “Calibration Procedure Status”
menu. This menu will appear automatically after starting the zero or span gas
calibration. The status of the running calibration will be shown and can be canceled at
any time while running by pressing the F2 key. See Section 4.2.4.1 for the complete
menu displays.

4.3.1.8 A

DVANCED CALIBRATION METHODS

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Calibration parameters…

Advanced calibration methods…

MLT/CH1/R1 37.50 ppm

-- Advanced Calibration Methods --

Start zero calibration procedure for all channels !

Start span calibration procedure for all channels !
Start zero+span calibration procedure !

Start zero+span calibration procedure for all channels!
Start basic calibration procedure !

Cancel all running procedures !
Info…

Measure Status… Back…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓
keys. Start the function with the
Enter ↵↵↵↵ or →→→→ keys or cancel
and go back with the F4 or ←←←←
key.

If asked, confirm with the F2 key
or cancel and go back with the
F4 or ←←←← key.

68

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

This menu has the following functions:

• Start a zero calibration of all measurement ranges for all channels simultaneously.

• Start a span calibration of all measurement ranges for all channels simultaneously.

• Start the zero and span calibration together for the current channel.

• Start the zero and span calibration together for all channels.

• Start the basic calibration procedure for the current channel. A zero and a span

calibration will start automatically. If the calibration is successful, the calibration

deviations will be reset to zero.
Before starting any calibration, make sure that the signal is stable.
In order to start the zero and span calibration separately, or to calibrate each channel

separately, or to calibrate the measurement ranges separately with span gas, use the
“Analyzer Module Calibration” menu (See Section 4.3.1.7) or the “Calibration
Procedure Setup” menu (See Section 4.3.1.5).

To cancel any running calibration procedure, use the “Cancel all running procedures !”
function.

The F2 key shows the “Analyzer Channel Status” menu as described in detail in
Section 4.2.1. From that menu and its submenus can be found that status of the
current channel for:

Failures Maintenance requests Function controls

Alarms Events Hours of operation

And the operational settings of the current channel:

Range settings Response time (t90)

Select the “Info…” submenu to see the calibration status of each channel:

MLT/CH1/R1 37.50 ppm

-- State of Calibration Procedures --

Channel –1: Ready
Channel –2: Ready
Chennel –3: Ready

Measure Back…

F1 F2 F3 F4 F5

748446-C Rosemount Analytical March 2001

↵↵↵↵

Model CAT 200 Continuous Analyzer Transmitter

69

TARTUP AND OPERATION

S

4.3.1.9 Z

ERO GAS PARAMETERS

This menu is used to set up the zero gas concentration for all ranges of the current
channel. The concentration units (ppm, ppb, %, etc.) are determined by the setup of
the current channel. See Section 4.3.10.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Calibration parameters…

Zero gases…

MLT/CH1/R1 37.50 ppm

-- Zero Gas Definition --

Zero gas concentration (all ranges): 0.00 ppm

Measure Back…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Change the variable parameter with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.

70

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.3.2 A

LARM PARAMETERS

This menu and its submenus controls the settings for the alarms for various
parameters of each channel. If the selected parameter signal exceeds the alarm limit,
a corresponding alarm message is displayed. For concentration this will be flag icons
at the alarm values on the bargraph in the single component display.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Alarm parameters…

MLT/CH1/R1 37.50 ppm

-- Alarms Setup --

Alarm delay: 0.2 s

Concentration…
Concentration average…
Flow…
Pressure…
Temperature…
Calculator-1…
Calculator-2…
Calculator-3…
Calculator-4…

Measure Status… Back… ClrAla !

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Change to the submenu or select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Change the variable parameter with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.
Use the F5 key (ClrAla ! = Clear Alarm) to clear an active alarm.. This should be done

only after the signal has returned to the allowed range to reset the alarm for new
events.

Alarm delay:

The alarm delay establishes the delay time after an out of tolerance condition occurs
before the alarm is set. The range is 0.0 to 30.0 seconds.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

71

TARTUP AND OPERATION

S

The F2 key shows the “Analyzer Channel Status” menu as described in detail in
Section 4.2.1. From that menu and its submenus can be found that status of the
current channel for:

Failures Maintenance requests Function controls

Alarms Events Hours of operation

And the operational settings of the current channel:

Range settings Response time (t90)

Some alarm setup items may not be available if not installed in the analyzer. For
instance, if no flow sensor is installed, a corresponding message will appear when
attempting to select it.

72

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.3.2.1 A

LARM SETUP AND CONTROL

The following is an example of setting the alarm parameters using “Concentration.”
The other functions are set in the same way.

From the “Alarms Setup” menu highlight and select the desired function and the
display changes to the following:

MLT/CH1/R1 37.50 ppm

-- Concentration Alarm Setup --

Alarm generation is: Off

Level for Low-Low alarm: -10.000 ppm
Level for Low alarm: 0.000 ppm
Level for High alarm: 100.000 ppm
Level for High-High alarm: 1000.000 ppm

Low-Low alarm: Off
Low alarm: Off
High alarm: Off
High-High alarm: Off

Measure Channel Back…

F1 F2 F3 F4 F5

↵↵↵↵

Use the F3 key to change to the setup menu of the other channels.
Before beginning the alarm parameter setup, turn off the alarms at the “Alarm

generation is:” line. Otherwise, an alarm may trigger while the parameter is being
changed.

Next adjust the four available alarm levels as desired. The units and possible range of
values depends on the parameter chosen. Negative values can be entered by
selecting the number with the Enter ↵↵↵↵ or →→→→ key and then pressing F4 (±) to change
the sign.

Select one of the following to activate the alarm for the parameter limits selected:
On: In this mode the alarm will activate only as long as the signal exceeds the

established level. The alarm will deactivate as soon as the signal is back within the
allowed values.

On (Hold Alarm): In this mode the alarm will activate when the signal exceeds the
established level and will remain activated even when the signal is back within the
allowed values. To reset the alarm, use the F5 key on the “Alarms Setup” menu to
clear the alarm.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

73

TARTUP AND OPERATION

S

4.3.3 R

ANGE PARAMETERS

This menu and its submenus allow setup of the range parameters for the current
channel. Press the F3 key to change to another channel.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Range parameters…

MLT/CH1/R1 37.50 ppm

-- Range Parameters --

Begin / end of ranges…

Response times (t90)…
Autoranging control…

Actual range number: 1
Range and calibration control: Manual

Actual begin or range: 0.00 ppm
Actual end of range: 100.00 ppm

Measure Channel Back…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Change to the submenu or select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Change the variable parameter with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.

Actual range number:

This variable allows selecting of the actual range number of the current channel from
1 to 4. The range nu mber will be set automatically if the auto ranging or the program
I/o is enabled. The range number will be controlled by digital inputs if the input I/o
module is enabled.

Range and calibration control:

This parameter is used f or autoranging of the current channel. The following options
are available:

74

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

• Manual – The range number must be changed manually. The “Switch level

hysteresis” is disabled. See Section 4.3.3.3.

• Self/Automatic – Autoranging is performed by comparing the current

measurement value with the maximum range. In this case, the value of “Switch
level hysteresis” is enabled (See Section 4.3.3.3).

Note:

If the autorange mode is selected, the t90 times of the corresponding channel

must be set to the same value (See Section 4.3.3.2). In addition, all offset

values of the channel must be set to zero.

• Program I/O Module – In this case, the autoranging is controlled by the

programmable I/O board (I/O with three alarms). The value of “Switch level
hysteresis” is enabled (See Section 4.3.3.3).

• Inputs I/O module – In this case, the autoranging is controlled by the digital input

(DIO). The value of “Switch level hysteresis” is enabled (See Section 4.3.3.3).

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

75

TARTUP AND OPERATION

S

4.3.3.1 O

FFSET AND SPAN OF RANGE

This menu is used to setup the offset and span of each range for the current channel.
Press the F3 key to change to another channel.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Range parameters…

Begin / end of ranges…

MLT/CH1/R1 37.50 ppm

Range –1 begin: 0.00 ppm

Range –1 end: 50.00 ppm
Range –2 begin: 0.00 ppm

Range –2 end: 250.00 ppm
Range –3 begin: 0.00 ppm

Range –3 end: 2500 ppm
Range –4 begin: 0.00 ppm

Range –4 end: 10000 ppm

Measure Channel Back…

-- Begin / End of Ranges --

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Select any digit with the ←←←← or →→→→ key and adjust the value with the ↑↑↑↑ or ↓↓↓↓ keys. Or,

adjust the entire value with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.
Allowed minimum and maximum range values can be established between the

fullscale concentration of range 1 and the fullscale concentration of range 4. See
“Absolute range upper limit” and “Absolute range lower limit” in the “Autoranging
Control” menu in Section 4.3.3.3.

76

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.3.3.2 R

ESPONSE TIMES (T

90

)

This menu is used to setup the response time (t90-time) of each range for the current
channel. Press the F3 key to change to another channel. The response time is defined
as the time necessary to sample the test gas until the analyzer displays 90% of the
concentration after a change in concentration.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Range parameters…

Response times (t90)…

MLT/CH1/R1 37.50 ppm

-- Response Times --

Range –1: 2.00 s

Range –2: 2.00 s
Range –3: 2.00 s
Range –4: 2.00 s

Actual range number: 1
t90-time: 2.00 s

Measure Channel Back…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Select any digit with the ←←←← or →→→→ key and adjust the value with the ↑↑↑↑ or ↓↓↓↓ keys. Or,

adjust the entire value with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.
Notes:

• The range of values is between 0.03 and 28 seconds for each range of a channel.

• The minimum increment of response time is 0.3 seconds.

• For normal operation, the response time should not be less than 2 s.

• For calibrations, the value should be 2 s.

• The response times established here do not constitute the response time of the

analyzer as a whole.

• If autoranging is used (See Section 4.3.3.3), the response times must be the

same for each channel.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

77

TARTUP AND OPERATION

S

4.3.3.3 A

UTORANGING CONTROL

This menu is used to setup the autoranging parameters for the current channel. Press
the F3 key to change to another channel. If autoranging is enabled (See Section

4.3.3), the best range f or the current concentration will be sele cted automatically.
Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Range parameters…

Autoranging control…

MLT/CH1/R1 37.50 ppm

-- Autoranging Control --

View actual switch levels…

Switch level hysteresis: 10 %
Usage of range –1: Enabled
Usage of range –2: Enabled
Usage of range –3: Enabled
Usage of range –4: Enabled

Absolute, range upper limit: 1000000 ppm
Absolute, range lower limit: 0.00 ppm

Measure Channel Back…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Select the variable with the Enter ↵↵↵↵ or →→→→ keys.
Select any digit with the ←←←← or →→→→ key and adjust the value with the ↑↑↑↑ or ↓↓↓↓ keys. Or,

adjust the entire value with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.
Notes:

• “Range and calibration control” must be enabled in order for autoranging to

function. See Section 4.3.3.

• The beginning of the range must be zero for all four ranges of the current channel.

See Section 4.3.3.1.

• All four response times of the current channel must have the same value. See

Section 4.3.3.2.

• The span gas concentration must be in the correct range. See Section 4.3.1.3.

• Each of the ranges can be enables or disabled and range 4 does not have to be

the biggest range.

78

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

• Absolute, range lower limit: Normally this value should be zero except for
differential measurements. See Section 4.3.12.

• Absolute, range upper limit: This is set to 120% of the largest maximum range
value at initial operation. This is the maximum value that will be accepted for end
of range.

Switch level hysteresis:

This value determines the hysteresis between the ranges for autoranging. T his is the
difference between the concentration values that the range switches when the value is
increasing and the point where the range switches when the value is decreasing.
Hysteresis prevents the rapid toggling of the range when the concentration value is
near a range switch point. Selection of the value will depend upon the expected rate of
change in concentration values versus the need to keep readings within a specified
percentage of the range limit.

The value applies to all three switch points for the four ranges. The hysteresis is
calculated as a percentage of the current end of range value.

The following example is for a hysteresis value of 10% and end of range values of
500, 1000, 1500, and 2000 ppm respectively:

1350

900

Range

1 2 3 4

0 500 1000 1500 2000

450

Concentration ppm

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

79

TARTUP AND OPERATION

S

To view the actual switch levels, choose the “View actual switch levels” submenu
which displays a screen similar to the following:

MLT/CH1/R1 37.50 ppm

Range –1 up: 500 ppm
Range –1 down: --

Range –2 up: 1000 ppm
Range –2 down: 450 ppm

Range –3 up: 1500 ppm
Range –3 down: 900 ppm

Range –4 up: -­Range –4 down: 1350 ppm

Measure Channel Back…

-- Actual Switch Levels --

F1 F2 F3 F4 F5

↵↵↵↵

80

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

TARTUP AND OPERATION

S

4.3.4 C

ROSS INTERFERENCE COMPENSATION

This function performs the calculation of the influence of other components on the
result of the analyzed component. Each channel can have a maximum of three
interference components. Press the F3 key to switch to another channel and calculate
the cross interference compensation of those channels.

Cross compensation must be performed with pure gases or gases in an inert
atmosphere (CH4 or N2). Do not use mixed gases.

All channels for which interference compensation is being calculated must be
calibrated.

Main Menu Analyzer and I/O, expert controls & setup…

Analyzer module setup…

Cross interference compensation…

MLT/CH1/R1 37.50 ppm

-- Cross Interference Compensation --

Compensation is: Disabled

Selected interference component: 1
Cross interference source channel…
Interference factors…
Calculate factor for selected interference component !
Remove selected component !

1. Interference component: ----

2. Interference component: ----

3. Interference component: ----

Measure Channel Back…

F1 F2 F3 F4 F5

↵↵↵↵

Select a line with the ↑↑↑↑ or ↓↓↓↓ keys.
Select the variable or submenu with the Enter ↵↵↵↵ or →→→→ keys.
Select any digit with the ←←←← or →→→→ key and adjust the value with the ↑↑↑↑ or ↓↓↓↓ keys. Or,

adjust the entire value with the ↑↑↑↑ or ↓↓↓↓ keys.
Confirm the new variable with the Enter ↵↵↵↵ key or cancel and return to the last value

with the F2 key.

748446-C Rosemount Analytical March 2001

Model CAT 200 Continuous Analyzer Transmitter

81

TARTUP AND OPERATION

S

Calculation of cross interference compensation:

1. Select “Disabled” in the line “Compensation is.” Otherwise the result will be
influenced by previous values.

2. In the line “Selected interference component,” select the desired number of the
current interference component.

3. Press the Enter ↵↵↵↵ or →→→→ key in the line “Choose interference source channel…” to
change to the submenu “Channels” as shown below:

MLT/CH1/R1 37.50 ppm

-- Channels --

MLT13/CH1

MLT13/CH2
MLT13/CH3

Measure Back…

F1 F2 F3 F4 F5

↵↵↵↵

4. Select the desired interference source channel with the ↑↑↑↑ or ↓↓↓↓ keys and then
choose it with the ↵↵↵↵ or →→→→ key. The display will return to the “Cross Interference
Compensation” menu. The tag of the interference component will appear in one of
the last three lines of the menu. Its position will depend on the selected
interference component number selected .

5. Repeat the last three steps as necessary to select all interference components
(maximum 3).

6. Begin the flow of the interference component into the sample gas channel and wait
for a stable reading.

7. Start the function “Calculate factor for selected interference component !” to
automatically calculate the interference component factor.

82

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter