Rosemount CAT 7 Thermal Conductivity Transmitter-Rev B Manuals & Guides

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Page 1

Instruction Manual

748451-B March 2002

Model CAT7

Thermal Conductivity Analyzer

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Page 2

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

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

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

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

sentative for clarification.

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

• Inform and educate your personnel in the proper installation, operation, and mainte-

nance of the product.

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

proper electrical and pressure sources.

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

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

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

The information contained in this document is subject to change without notice.

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

Emerson Process Management

Rosemount Analytical Inc. Process Analytic Division

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

http://www.processanalytic.com

Page 3

Model CAT7

PREFACE...........................................................................................................................................1

Definitions ...........................................................................................................................................1

safety Summary..................................................................................................................................2

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

Documentation....................................................................................................................................5

Compliances .......................................................................................................................................5

1.0 DESCRIPTION AND SPECIFICATIONS..............................................................................1-1

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

1-2 Thermal Conductivity Cell......................................................................................................1-1

1-3 Electronic Circuitry.................................................................................................................1-4

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

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

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2.0 INSTALLATION ....................................................................................................................2-1

2-1 Site Preparation.....................................................................................................................2-1

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

2-3 Flow Diagrams.......................................................................................................................2-1

2-4 Location and Mounting ..........................................................................................................2-1

a. Location...........................................................................................................................2-1

b. Mounting .........................................................................................................................2-1

2-5 Unpacking..............................................................................................................................2-3

2-6 Gas Requirements.................................................................................................................2-3

2-7 Calibration Gas Requirements ..............................................................................................2-3

a. Sample Gas Composition ...............................................................................................2-3

2-8 Suppressed-Zero Ranges .....................................................................................................2-3

2-9 Leak Check............................................................................................................................2-3

2-10 Gas Connections ...................................................................................................................2-4

2-11 Recorder Output Selection and Cable Connections .............................................................2-8

a. Standard (Non-linearized) Voltage Output......................................................................2-8

b. Linearized Voltage Output (Optional)..............................................................................2-8

c. Isolated 4 to 20 mA Current Output (Optional) ...............................................................2-8

2-12 Alarms (Optional)...................................................................................................................2-10

2-13 Linearized Voltage, Two Ranges (Optional)..........................................................................2-12

2-14 Linearized Voltage and Isolated 4 to 20 mA Current Output (Optional)................................2-12

2-15 Electrical Power Connections................................................................................................2-13

3.0 OPERATION .........................................................................................................................3-1

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

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

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

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

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

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Instruction Manual

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4.0 THEORY................................................................................................................................4-1

4-1 Thermal Conductivity Cell and Associated Bridge Adjustments ...........................................4-1

4-2 Master Board .........................................................................................................................4-1

a. Functions Associated with AR1 ......................................................................................4-1

b. Coarse zero and zero-suppression.................................................................................4-2

c. Functions Associated with AR2 ......................................................................................4-2

d. Meter ...............................................................................................................................4-2

e. Output Selection Switch S1 ............................................................................................4-2

4-3 Voltage Output Linearizer Board Option ...............................................................................4-2

4-4 Isolated 4 to 20 mA Current Output Board Option ................................................................4-4

4-5 Bridge Power Supply .............................................................................................................4-4

4-6 ±15 Volt Power Supply ..........................................................................................................4-4

4-7 Detector Blocks .....................................................................................................................4-4

4-8 Case Temperature Controller Assembly ...............................................................................4-4

4-9 Dual Alarms Option ...............................................................................................................4-5

5.0 SERVICE AND MAINTENANCE ..........................................................................................5-1

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

5-2 Electronic Circuitry.................................................................................................................5-4

a. Amplifier Zero Adjustments.............................................................................................5-4

b. Bridge Balance and Range Sensitivity Adjustments.......................................................5-4

c. Case Temperature Controller .........................................................................................5-5

d. Dual Alarm Module (Optional).........................................................................................5-5

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

Model CAT7

6.0 REPLACEMENT PARTS ......................................................................................................6-1

6-1 Matrix .....................................................................................................................................6-1

6-2 Circuit Board Replacement Policy .........................................................................................6-3

6-3 Replacement Parts ................................................................................................................6-4

7.0 RETURN OF MATERIAL ......................................................................................................7-1

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

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

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

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

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Model CAT7

Figure 1-1. CAT7 Controls, Adjustments, Ports .......................................................................... 1-2

Figure 1-2. Fuse Location............................................................................................................ 1-2

Figure 1-3. CAT7 – Exploded View ............................................................................................. 1-3

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

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

Figure 2-3. Gas Connections – Bottom View of Analyzer ........................................................... 2-4

Figure 2-4. Connection of Analyzer Using Sealed-In Reference Gas to Associated Gas .......... 2-5

Figure 2-5. Connection of Analyzer Using Flowing Reference Gas to Associated Gas Selector

Figure 2-6. Intrinsic Safety Box ................................................................................................... 2-7

Figure 2-7. Intrinsic Safety Box Interconnect .............................................................................. 2-7

Figure 2-8. Master Board............................................................................................................. 2-9

Figure 2-9. Alarm Adjustments ..................................................................................................2-10

Figure 2-10. Typical Alarm Settings .......................................................................................... 2-11

Figure 2-11. Case Heater Temperature Control Board............................................................. 2-13

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

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LIST OF ILLUSTRATIONS

Panel...................................................................................................................... 2-6

LIST OF TABLES

Table 1-1. Available Gas Selector Panels................................................................................... 1-5

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

DRAWINGS

613561 Schematic Diagram, Bridge Power Supply - Regulated 5 to 15V 619710 Schematic Diagram, 15V Power Supply 624003 Schematic Diagram, Temperature Controller 652813 Schematic Diagram, Isolated Current Output 652863 Schematic Diagram, Linearizer Board 654616 Schematic Diagram, Master Board 661200 Assembly Instructions, CAT7 661203 Assembly, Chassis 661318 Installation Drawing, CAT7 661540 Assembly, Temperature Control 661541 Assembly, Meter 661562 Wiring Diagram, CAT7

(LOCATED IN REAR OF MANUAL)

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

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Model CAT7

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

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Instruction Manual

Model CAT7

PREFACE

The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the CAT7 Thermal Conductivity Analyzer.

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

DEFINITIONS

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

DANGER .

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

WARNING .

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

CAUTION.

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

NOTE

Highlights an essential operating procedure, condition or statement.

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

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Instruction Manual

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Model CAT7

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 the Model CAT7 Thermal Conductivity Analyzer 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.

AUTHORIZED PERSONNEL

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

DANGER.

ELECTRICAL SHOCK HAZARD

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

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

NOTE

Before supplying electrical power to the analyzer, remove power to the bridge by disconnecting the red lead from the bridge to TB1-1 or TB1-2 (depending on the bridge polarity). See drawing 661562. To safeguard against filament damage, this lead should remain disconnected until proper gas flow has been established.

DANGER

EXPLOSION HAZARD

Do not operate the Model CAT7 Explosion-Proof Analyzer without the lens cover in place and completely secured, unless location have been determined to be non-hazardous.

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

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Instruction Manual

Model CAT7

DANGER

EXPLOSION HAZARD

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

If explosive gases are introduced into this analyzer, the sample containment system must be carefully leak-checked upon installation and before initial startup, during routine maintenance and any time the integrity of the sample containment system is broken, to ensure the system is in leak-proof condition. Leak-check instructions are provided in Section 2-9.

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

WARNING .

PARTS INTEGRITY

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

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March 2002

WARNING.

HIGH PRESSURE GAS CYLINDERS

This instrument requires periodic calibration with a known standard gas. See also General Precautions for Handling and Storing High Pressure Gas Cylinders, page P-4.

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

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Instruction Manual

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Model CAT7

GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH

PRESSURE GAS CYLINDERS

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

Compressed Gas Association 1235 Jefferson Davis Highway Arlington, Virginia 22202

Used by Permission

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

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

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

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

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

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

7. No part of cylinder should be subjected to a temperature higher than 125 permitted to come in contact with any part of a compressed gas cylinder.

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

F (52°C). A flame should never be

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

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Instruction Manual

Model CAT7

DOCUMENTATION

The following CAT7 Thermal Conductivity Analyzer instruction materials are available. Contact Customer Service or the local representative to order.

748451 Instruction Manual (this document)

COMPLIANCES

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 + H

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March 2002

Canada

Ex d e m IIB + H

European Union

ATEX, Category 2, Zone 1, IIB + H

USA/Canada

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

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

0081

EEx d e m II B (+H2) T4

LCIE 00 ATEX 6009 X

II 2 G

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.

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

NAMUR

N96

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

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Model CAT7

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SECTION 1

DESCRIPTION AND SPECIFICATIONS

The Model CAT7 Thermal Conductivity Analyzer is designed to continuously measure the concentration of a single component of interest in a flowing gas mixture. The measurement is based on the different thermal conductivity's of the individual components of the sample stream. The method is especially well suited to analysis of two-component sample streams. However, analysis of multi-component streams is possible if the various components of the background gas occur in relatively constant ratio, or have similar thermal conductivity's.

Each Model CAT7 Analyzer is factory-assembled, as ordered, for determination of a specified component, with specified range of concentration, contained in a background component or background mixture of known composition. Typical examples include: 0 to 100 % hydrogen in nitrogen; 20 to 50 % helium in methane; and 0% to 3% carbon dioxide in air. If so ordered, the instrument is provided with two or three ranges; selectable via a side-panel switch. Information specific to the individual instrument is provided in the data sheet inserted in the back of this instruction manual.

A Model CAT7 Analyzer consists of an analyzer module, Section 1-1, and, if ordered, an accessory gas selector panel, Section 1-4.

1-2 THERMAL CONDUCTIVITY CELL

The thermal conductivity cell is a metal block with separate passages for the sample and reference gases. In all applications, the sample passage receives a continuous flow of sample gas. Depending on the application, the reference passage may receive a continuous flow of reference gas, or may have the reference gas sealed within.

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

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

1-1 ANALYZER MODULE

The analyzer module is supplied in an explosion-proof enclosure suitable for installation in hazardous locations classified as Zone 1, Groups II B (+H Group II B (+H

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

), T4, Category 2, Zone 1,

), T4.

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

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Adj

748451-B March 2002

AC Power Port

Model CAT7

Signal Output, Alarm Ports

Alarm

Figure 1-1. CAT7 Controls, Adjustments, Ports

Range Select

Zero

ust

Span

Fuse

Figure 1-2. Fuse Location

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

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Model CAT7

Instruction Manual

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Chassis Assembly

Meter Assembly

Alarm Module

Figure 1-3. CAT7 – Exploded View

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

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Model CAT7

1-3 ELECTRONIC CIRCUITRY

The analyzer module contains solid-state circuitry that conditions the bridge-imbalance signal as required to provide readout on the meter. In addition, a field-selectable output for a voltage-type recorder is provided as standard. A field-selectable output of 4 to 20 mA for a current-actuated recorder or other device is obtainable through use of an optional plug-in circuit board. A calibration curve can be used to convert meter or recorder readings into concentration values. Typical calibration curves are supplied for standard ranges. Calibration curves for special ranges are available as options.

To avoid use of a calibration curve in an application where it would otherwise be required, the analyzer may be equipped with an optional linearizer board. If so, the linearizer is factory set for a given range only, and is not usable on another range. Note that a linearizer is usable only if non-linearity at mid-

scale does not exceed approximately 20% of fullscale.

1-4 GAS SELECTOR PANEL

If so ordered, the analyzer module is provided with an appropriate gas selector panel, Figure 1-4. The gas selector panel permits selection, flow adjustment, and flow measurement for the various gases: sample; flowing reference gas, if used; and downscale and upscale calibration gases. Proper choice of a gas selector panel depends on:

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

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

Reference Gas

Flow Meter

Downscale Calibration Gas Needle Valve

DOWNSCALE

CAL GAS

UPSCA LE

CAL GAS

Upscale Calibration Gas Needle Valve

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

REF

SAMPLE

Figure 1-4. Typical Gas Selector Panel

Sample/Calibration Gas Flow Meter

SAMPLE

REFERENCE

Sample Gas Needle Valve

Reference Gas

Needle Valve

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

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Model CAT7

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

1-5 SPECIFICATIONS

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

Zero Drift

Span Drift

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

Cell Response Time

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

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

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

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

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

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

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

Output Voltage

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

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

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

DESCRIPTION PART NUMBER

Table 1-1. Available Gas Selector Panels

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

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

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

117°F (47°C).

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

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

loads

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

rosion-resistant filaments available on order

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

Enclosure....................................... Zone 1, Groups II B (+H

(+H

), T4

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

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

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

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

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

), T4, Category 2, Zone 1, Group II B

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

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Model CAT7

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SECTION 2

INSTALLATION

2-1 SITE PREPARATION

This section provides information that may be required prior to installation.

For outline and mounting dimensions of the analyzer drawing 661318. For outline and mounting dimensions of the gas selector panel, see Figure 2-1, and Figure 2-2.

2-2 CUSTOMER ELECTRICAL CONNECTIONS

Customer electrical connections are shown in Figure 2-7 and drawing 661562.

2-3 FLOW DIAGRAMS

For gas connections, refer to appropriate flow diagram:

• Analyzer using sealed reference gas, Figure 2-4.

• Analyzer using flowing reference gas, Figure 2-5.

2-4 LOCATION AND MOUNTING

a. Location

Proper location for the analyzer depends on two basic considerations:

•

Accessibility to the sampling point

•

Protection of the instrument

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

The analyzer should be mounted in a clean, dry atmosphere. Ambient temperature should be within the range of

F to 100 F (0oC to 38oC).

b. Mounting

The analyzer is designed for wall mounting. Refer to drawing 661318.

10.25 [260]

SAMPLE

Span Gas In

To Analyzer

Sample In

Zero Gas In

8.25 [210]

Mounting Holes (4) NO. 8 Flat Head Screw

ZERO SPAN

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

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

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Model CAT7

Sample Gas

To Analyzer Sample Inlet

To Analyzer Ref Gas Inlet

Downscale Calibration Gas

1.25 [32]

DOWNSCALE

CALIBRATION GAS

10.25 [260]

8.25 [210]

REF SAMPLE

UPSCALE

CALIBRATION GAS

3.25 [83]

.12

[3]

Mounting Holes (4) NO. 8 Flat Head Screw

Ref Gas

Upscale Calibration Gas

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

SAMPLE

REF

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

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2-5 UNPACKING

The Model CAT7 Thermal Conductivity Analyzer is a precision instrument and should be handled carefully. Carefully examine the shipping carton and contents for signs of damage. Immediately notify the carrier if the carton or its contents are damaged. Retain the carton and packing material until the instrument is operational.

2-6 GAS REQUIREMENTS

The Model CAT7 requires cylinder gases appropriate to the particular application (refer to the Data Sheet in the rear of this manual). Suitable gases are available from various suppliers.

2-7 CALIBRATION GAS REQUIREMENTS

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

a. Sample Gas Composition

WARNING

POSSIBLE EXPLOSION HAZARD

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

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

2-9 LEAK CHECK

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

In a typical application, the sample gas consists of two components, for example: hydrogen in nitrogen. In this example, hydrogen is designated the “measured component” and nitrogen constitutes the “background gas.”

2-8 SUPPRESSED-ZERO RANGES

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

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

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

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

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2-10 GAS CONNECTIONS

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

copper or stainless steel tubing, depending on whether the sample stream is corrosive.

Connect sample/calibration gas lines to fittings tagged “INLET” on bottom of analyzer. Connect appropriate vent line to fitting labeled “OUTLET.”

Follow similar procedure for reference gas, if any.

GAS INLET

(CH1)

OUTLET

ZERO GAS

INLET1

GAS

OUTLET

(CH1)

SAMPLE

GAS INLET

SPAN GAS

1 INLET

GAS INLET

(CH2)

SPARE SPARE

SPAN GAS

2 INLET

GAS

OUTLET

(CH2)

Figure 2-3. Gas Connections – Bottom View of Analyzer

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

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March 2002

Sample In

Zero Standard Gas

Span Standard Gas

Needle Valves

113357 or 113920

Gas Selector Panel

Flowmeter

Model CAT7

Thermal Conductivity Analyzer

Reference Gas Sealed-In

Thermal Conductivity Cell

To Vent

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

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

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Instruction Manual

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A. DIFFERENT REFERENCE GAS AND CALIBRATION GAS

Model CAT7

Reference Gas

Sample Gas

Downscale Calibration Gas

Upscale Calibration Gas

Needle Valves

117195 or 118210

Gas Selector Panel

Reference

Gas

Flowmeter

Sample

Gas

Flowmeter

B. REFERENCE GAS ALSO USED AS CALIBRATION GAS

Downscale Calibration Gas Used as Reference

Needle Valves

117195 or 118210

Gas Selector Panel

Model CAT7

Thermal Conductivity Ana-

Thermal Conductivity Cell

Thermal Conductivity Ana-

lyzer

Model CAT7

lyzer

Sample

Vent

Reference

Vent

Sample Gas

Downscale Calibration Gas

Upscale Calibration Gas

Reference

Gas

Flowmeter

Sample

Gas

Flowmeter

Thermal Conductivity Cell

Sample

Vent

Reference

Vent

Figure 2-5. Connection of Analyzer Using Flowing Reference Gas to Associated Gas Selector Panel

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

Page 25

Model CAT7

Instruction Manual

748451-B

March 2002

LINE

NEUT

GND

1234

Figure 2-6. Intrinsic Safety Box

ALARM #1 NO

ALARM #1 COM

ALARM #1 NC

ALARM #2 NO

ALARM #2 COM

+VOLT OUT

-VOLT OUT

+CUR OUT

-CUR OUT

1234 121234

ALARM #2 NC

Figure 2-7. Intrinsic Safety Box Interconnect

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

Page 26

Instruction Manual

748451-B March 2002

CAUTION

Do not plug or restrict vents.

2-11 RECORDER OUTPUT SELECTION AND CA-

BLE CONNECTIONS

If a recorder, controller, or other output device is used, connect it to the analyzer (refer to Figure 2-6 and Figure 2-7) via a number 22 or number 24 AWG two-conductor shielded cable. Route the cable through conduit to the analyzer, and into the case through the appropriate opening shown in Figure 1-1.

NOTE

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

Model CAT7

b. Linearized Voltage Output (Optional)

1. Verify that Voltage-Output Linearizer Board is properly inserted in J102 on the Master Board.

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

a. Verify that TB2-1 is jumpered to

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

b. Set S1 for desired voltage: 5V,

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

3. In the Intrinsic Safety Box, connect the recorder cable to the terminals labeled +VOLT OUT and –VOLT OUT (Figure 2-7).

NOTE

Output selection and cable connections for voltage-actuated and current-actuated devices are explained in Sections 2-11a through 2-12b.

a. Standard (Non-linearized) Voltage Out-

put

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

a. Verify that TB2-1 is jumpered to

TB2-2.

b. Set S1 for desired voltage: 5V,

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

2. In the Intrinsic Safety Box, connect the recorder cable to the terminals labeled +VOLT OUT and –VOLT OUT (Figure 2-7).

NOTE

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

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

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

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

c. Isolated 4 to 20 mA Current Output

(Optional)

5. Verify that the Isolated 4 to 20 mA Current Output Board is properly inserted in J103 on the Master Board.

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

c. Verify that TB2-1 is jumpered to

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

7. In the Intrinsic Safety Box, connect the

recorder cable to the terminals labeled +CUR OUT and -CUR OUT (Figure 2-7).

8. Connect the cable to the recorder input

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

4. Ground shield on one end only.

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

Page 27

Model CAT7

230

Instruction Manual

748451-B

March 2002

POWER

HEATER POWER

FAN

- + - +

CUR

VOLT

OUT

R4 R9 R7 R22 R26 R6 R8

TB4

R15

F13

R12

R10

R14

R19R21 R18

AR1

R11

R17R20

R24

R16

6 5 4 3 2 1

BOARD

OPTIONS

RESISTOR SELECT

R27

RANGE

R1 R5 C3

SPAN R3 R2

METER

R23

TB2

TP1 TP2

1 2 3 4

TB5

1 2 3 4 5 6 7 8

TB3

J101 J100

TP3 TP4 TP5

J103 J102

TB1

6 5 4 3 2 1

DETECTOR

R100

Used to select voltage output range: 5V, 1V, 0.1V, or .01V AR1 gain adjust. Permits adjustment of AR1 gain from

X1 to X100, to establish the sensitivity desired for Range 1. This is the highest sensitivity range. AR1 zero adjust. Used to eliminate voltage offset within AR1 and Bridge, and provide zero suppression. Setting determines attenuation factor applicable to AR2 output, Range 3. Setting determines attenuation factor applicable to AR2 output Range 2. Permits adjusting meter fullscale to agree with recorder fullscale Used to eliminate voltage offset within AR2.

Sets the stable ±10 V source.

.01V .1V 1V 5V

DETAIL OF S1

R6, R8, R26

R22

R15 R16

ADJUSTMENTS

Figure 2-8. Master Board

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

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Instruction Manual

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2-12 ALARMS (OPTIONAL)

The analyzer is factory configured per customer order and requires no user adjustments.

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

Deadband Potentiometer ALARM 1

LED Indicator ALARM 1

Deadband Potentiometer ALARM 2

Model CAT7

deadband

SET

POINT

deadband

If the instrument has this option, the analyzer will have setpoint adjustment potentiometers: Alarm 1 (the Low Alarm) and Alarm 2 (the High Alarm) (Figure 1-1) and Deadband on the alarm module (see Figure 2-9).

NOTE

Do not adjust the setpoints on the alarm module (Figure 2-9). Use the adjustments from the exterior of the analyzer (Figure 1-1).

The power and input wiring (18 or 20 AWG) is routed into the intrinsic safety box. (see Figure 2-6).

The alarm relay is in energized mode when power is applied. Wire output to the appropriate contact (see Figure 2-7). The Form C relay contacts are rated at 5 A, 120 VDC and 1 A, 120 VAC, resistive loads.

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

LED Indicator ALARM 2

SET

POINT

Front View Of Alarm Module

span

Figure 2-9. Alarm Adjustments

The following is recommended:

1. A fuse should be inserted into the line between the customer-supplied power supply and the alarm module terminals in the intrinsic safety box..

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

NOTE

The Zero and Span for setting the input voltage from the analyzer has been set at

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

the factory. To check it, see Section 5-2d.

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

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Model CAT7

Instruction Manual

748451-B

March 2002

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

Alarm 1 Relay

The ALARM 1 relay coil is de-energized when the meter needle moves downscale through the value that corresponds to setpoint minus deadband. This relay coil is energized when the needle moves upscale through the value that corresponds to setpoint plus deadband (see Figure 2-10).

Alarm 2 Relay

The ALARM 2 relay coil is de-energized when the meter needle moves upscale

through the value that corresponds to the setpoint plus deadband. This relay coil is energized when the needle moves downscale through the value that corresponds to setpoint minus deadband (see Figure 2-10).

Fail-safe Applications

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

A. Typical ALARM 1 Setting (LOW)

DEADBAND SET FOR

20% OF FULLSCALE

B. Typical ALARM 2 Setting (HIGH)

DEADBAND SET FOR

10% OF FULLSCALE

INPUT SIGNAL

Percent of Fullscale

INPUT SIGNAL

Percent of Fullscale

When input signal moves upscale through this point, the

coil of ALARM 1 relay (K1) is energized, providing continuity between the common and normally-closed contacts of the relay.

ALARM 1 Setpoint

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

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

ALARM 2 Setpoint

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

Figure 2-10. Typical Alarm Settings

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Instruction Manual

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Model CAT7

2-13 LINEARIZED VOLTAGE, TWO RANGES (OP-

TIONAL)

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

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

a. Verify that TB2-1 is jumpered to

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

b. Select desired range on S1.

3. In the intrinsic safety box (Figure 2-7) connect recorder cable to the terminals labeled +VOLT OUT and –VOLT OUT.

NOTE

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

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

2-14 LINEARIZED VOLTAGE AND ISOLATED 4

TO 20 MA CURRENT OUTPUT (OPTIONAL)

1. Verify that the Voltage Output Linearizer Board is properly inserted in J102 on the Master Board (Figure 2-8).

2. Verify that the Isolated 4 to 20 mA Current Output Board is properly inserted in J103 on the Master Board (Figure 2-8).

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

a. Verify that TB2-1 is jumped to TB2-4,

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

b. Set S1 for the desired voltage: 5 V, 1

V, .1 V, or .01 V.

4. In the Intrinsic Safety Box (Figure 2-7) connect the recorder cable to the terminals labeled +VOLT OUT and –VOLT OUT.

NOTE

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

5. In the Intrinsic Safety Box (Figure 2-7) connect the recorder cable to the terminals labeled +CUR OUT and –CUR OUT.

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

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

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Model CAT7

Instruction Manual

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March 2002

2-15 ELECTRICAL POWER CONNECTIONS

DANGER

ELECTRICAL SHOCK HAZARD

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

NOTE

Before supplying electrical power to analyzer, disconnect the red lead from the bridge to TB1-1 or TB1-2 (depending on bridge polarity). This action disconnects power to the bridge (see drawing 661562). To safeguard against filament damage, this lead should remain disconnected until proper gas flow has been established.

SENSOR J18

400A 880 951E

R10 R11 R7 R8

CR1

R17 R16 R12 CR

TEMP CONTROL BD

The analyzer is supplied, as ordered, for operation on 107 to 127 or 214 to 254 VAC, 50/60 Hz, 250 watts. Verify that the power source conforms to the requirements of the individual instrument as noted on the name rating plate. Ensure that switches S2 on the Master Board (see Figure 2-8) and S3 on the case heater temperature control board (see Figure 2-11) are set to required voltage.

Electrical power is supplied to the analyzer via a customer-supplied three-conductor cable, type SJT, minimum wire size 18 AWG. Route the power cable through conduit and into the appropriate opening in the instrument case (see drawing 661318 and Figure 1-1). In the Intrinsic Safety Box, connect power cable leads to terminals 4 (LINE), 3 (NEUT), and 2 (GND). See Figure 2-7.

Set switch window for voltage required

POWER SUPPLY

R2R1

AR1

R13

R9 R5

TEST

J19

J11

R15

POWER LINE J5

3 2 1

R14

1 2 1 2 3

T.I.F. HEATER

J17

230

115

Figure 2-11. Case Heater Temperature Control Board

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-13

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Instruction Manual

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Model CAT7

2-14 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Page 33

Model CAT7

Instruction Manual

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March 2002

SECTION 3

OPERATION

3-1 ANALYZER CONTROLS AND ADJUST-

MENTS

Normal operation of the analyzer involves adjustments of only the ZERO, SPAN, and RANGE Switch, if provided. See Figure 1-1.

The various internal adjustments are factory set and normally do not require readjustment except after replacement of a circuit board or major component. Refer to Section 1.

3-2 GAS SELECTOR PANEL CONTROLS

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

3-3 STARTUP PROCEDURE

If explosive gases are introduced into this analyzer, the sample containment system must be carefully leak-checked upon installation and before initial startup, during routine maintenance and any time the integrity of the sample containment system is broken, to ensure the system is in leakproof condition. Leak-check instructions are provided in Section 2-9.

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

NOTE:

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

Board (depending on detector bridge polarity). This action disconnects power to the bridge. To safeguard against filament damage, this lead should remain disconnected until proper gas flow has been established. Refer to drawing 661562.

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

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

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

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

4. Apply power to the analyzer. The filaments will now begin to heat. Verify proper flow of sample gas and flowing reference gas, if used.

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

NOTE:

If ambient temperature is below 60°F (15.6°C), or if the temperature will go below 60°F (15.6°C) within the next six hours, allow a minimum of 12 hours for the instrument to stabilize.

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

NOTE:

Before supplying electrical power to the analyzer, disconnect the red lead from the bridge to TB1-1 or TB1-2 on the Master

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

Page 34

Instruction Manual

748451-B March 2002

Model CAT7

3-4 CALIBRATION

1. Set downscale calibration point as follows:

a. On the analyzer, set SPAN control to

mid-scale (five turns). If the analyzer has a RANGE Switch, set it at Range 1, the highest sensitivity range.

b. Admit downscale calibration gas to the

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

c. On the analyzer, adjust the ZERO

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

d. If a proper reading is unobtainable by

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

2. Set upscale calibration point as follows:

a. If the analyzer has a RANGE switch,

set it for the desired range.

b. Admit upscale calibration gas to the

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

c. Adjust the SPAN control so that the

reading on the meter or recorder is appropriate to the upscale calibration gas.

If a proper reading is unobtainable by adjustment of the SPAN control, refer to Section 1, Service and Maintenance.

After the downscale and upscale calibration points have been established, the analyzer is ready for routine operation.

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

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

Page 35

Model CAT7

Instruction Manual

748451-B

March 2002

SECTION 4

THEORY

4-1 THERMAL CONDUCTIVITY CELL AND AS-

SOCIATED BRIDGE ADJUSTMENTS

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

Sample Side

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

Reference Side

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

The Bridge Voltage Power Supply is connected, via a 20-ohm dropping resistor, to the bridge (See Section 4-5). The power supply output is adjusted to provide an appropriate voltage across bridge terminals 1(+) and 2(-). An electric current flows through the filaments, heating them and thus increasing their electrical resistance. The heat-dissipation rate for each filament depends on the thermal conductivity of the surrounding gas. Initially, with downscale calibration gas flowing through the sample and reference sides of the flow-through configuration, R26 is set for zero bridge-output signal. During subsequent analysis of the sample stream, any change in the relative proportions of the components passing through the sample side changes the thermal conductivity of the gas mixture, caus-

ing a temperature differential between sample and reference filaments. The resultant change in filament resistance unbalances the bridge.

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

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

4-2 MASTER BOARD

The Master Board, Figure 2-8, provides two stages of amplification utilizing integrated-circuit amplifiers AR1 and AR2.

a. Functions Associated with AR1

AR1: Gain Adjust Potentiometer R4.

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

Range Provisions: In the basic single-range Model CAT7, a jumper is connected from TB3-1 to TB3-4, thus routing the unattenuated output from AR1 directly to the non-inverting input of AR2. During factory assembly of a dual-range or triple-range instrument, the jumper is omitted and a RANGE Switch is connected as shown below. The output from AR1 is then routed to AR2 through a network that provides adjustable attenuation for ranges 2 and 3.

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Page 36

Instruction Manual

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RANGE AR1 OUTPUT ATTENUATION RANGE SWITCH POSITION TB3 POSITION

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

Model CAT7

Table 4-1. Range Switch Connections

b. Coarse zero and zero-suppression

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

c. Functions Associated with AR2

AR2 Zero Adjustment Potentiometer R1: This screwdriver-adjustable, factory-set trimming potentiometer is used to eliminate voltage offset within AR2. When the input signal is zero, R15 is adjusted so that the output signal also is zero.

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

d. Meter

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

e. Output Selection Switch S1

4-3 VOLTAGE OUTPUT LINEARIZER BOARD

OPTION

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

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

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

max.), the Voltage Out-

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

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

Page 37

Model CAT7

     

      

A. Sectional View of Thermal Conductivity Cell

Instruction Manual

748451-B

March 2002

Thermal Conductivity Cell Block

Sample Gas Out

Reference Filaments

Reference * Gas In

Sample Gas In

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

B. Functional Diagram of Bridge Circuit

0.5

Front Panel Zero Potentiometer

O-Ring Seals

Sample Filaments

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

0.5

Reference Flow

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

0.5 20

Resistor values are in ohms.

Bridge Power

Supply (+)

Figure 4-1. Thermal Conductivity Cell

Sample Flow

Bridge Power

Supply (-)

0.5

Page 38

Instruction Manual

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Model CAT7

4-4 ISOLATED 4 TO 20 MA CURRENT OUTPUT

BOARD OPTION

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

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

4-5 BRIDGE POWER SUPPLY

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

619710, power transformer T1 has three secondary that are used as follows:

38 VAC center-tapped secondary

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

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

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

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

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

90-volt center-tapped secondary

Drives a rectifier circuit on the optional Current Output Board. The transformer winding and the associated circuit constitute a floating power supply for the emitter-follower stage.

9.5 VAC secondary

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

4-7 DETECTOR BLOCKS

There are two types of detector configurations; flowing reference and sealed nitrogen reference. The sealed reference with nitrogen can be recharged by flowing nitrogen through the reference and closing the plugs. Three filament types are available: tungsten, Hitempco, and gold-sheathed tungsten.

4-6 ±15 VOLT POWER SUPPLY

The ±15 Volt Power Supply plugged into J101 of the Master Board, provides power for the various circuits. As shown in schematic

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

4-8 CASE TEMPERATURE CONTROLLER AS-

SEMBLY

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

Page 39

Model CAT7

Instruction Manual

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March 2002

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

4-9 DUAL ALARMS OPTION

Instruments with optional Dual Alarms have two pots on the front door which are used to select setpoints. The scales on the nameplate designate setpoints from 0 to 100%.

The module plugs into a socket, which is part of a terminal block mounted onto the chassis of the instrument. A marker on the alarm module indicates the function of each socket pin.

This unit is factory configured and requires no user adjustment. Pins for AC power (1, 2, and

3), alarm setpoint control (8, 10, 18, and 19),

and signal from analyzer circuitry (7 and 9) are wired at the factory.

Connections of the remaining pins depend upon the application. The relays are rated at

1.0 A, 120 VAC and 5.0 A, 120 VDC, form C,

resistive loads.

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

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

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SECTION 5

SERVICE AND MAINTENANCE

DANGER

POSSIBLE EXPLOSION HAZARD

If explosive gases are introduced into this analyzer, the sample containment system must be carefully leak-checked upon installation and before initial startup, during routine maintenance and any time the integrity of the sample containment system is broken, to ensure the system is in leakproof condition. Leak-check instructions are provided in Section 2-9.

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

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

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

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

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

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

a. If bridge balance is obtained with the

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

b. If bridge balance is unobtainable with

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

5-1 THERMAL CONDUCTIVITY CELL

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

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

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

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

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

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5-2 ELECTRONIC CIRCUITRY

a. Amplifier Zero Adjustments

The zero adjustments on the Master Board are factory set and normally do not require readjustment except after replacement of a major component. If readjustment becomes necessary, use following procedure:

AR2 Zero Adjustment (Refer to Figure 2-8):

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

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

3. Adjust R15 for 0 VDC output signal at TB4-2.

4. Restore connections to normal.

b. Bridge Balance and Range Sensitivity

Adjustments

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

Sensitivity Adjustment(s) are:

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

2. On the Master Board, set AR2 Gain Adjustment R4 so that reading on the recorder, if used, or on the meter is appropriate to the upscale calibration gas. Refer to data sheet or calibration curve. Range 1 sensitivity is now properly adjusted.

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

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

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

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

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

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

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

Bridge Voltage Adjustment

Bridge voltage is factory set as required for the application (see Data Sheet) and normally does not require readjustment unless the bridge power supply is replaced. Bridge voltage is measured between terminals 1(-) and 2(+), and is adjustable via R2. See schematic

613561.

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c. Case Temperature Controller

Refer to drawing 661540. Malfunction in this option can occur in three areas:

Heater

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

Temperature Sensor

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

Thermal Fuse

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

d. Dual Alarm Module (Optional)

This module is not user-serviceable. If problems occur, contact Rosemount Analytical service.

The module has Zero and Span potentiometers that set the 0 to 5 V input. To check these, adjust the analyzer for zero gas, set the Low Alarm set point to 0 %, and turn the Deadband counterclockwise. Adjust the Zero pot to trigger the alarm. Do the same for High Alarm (ALARM 2 on the front panel). The alarm span should agree with the analyzer meter span. Readjust the deadbands to the desired level. (See Figure 2-9 and Figure 2-10)

NOTE

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

1. Set the ZERO and SPAN controls to their midpoints (five turns).

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

3. On the Master Board, connect a digital voltmeter between TB3-1 and TP1 (polarity does not matter).

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

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

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

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

Range 2

5-3 SUPPRESSED ZERO ADJUSTMENT

If the instrument has suppressed-zero ranges and does not calibrate properly, adjust the potentiometers located on the Master Board (see Figure 2-8). Follow the startup procedure in Section 3-3. After the analyzer has stabilized, use appropriate calibration gases to make the following adjustments. Refer to Section 2-7 for information on selecting appropriate gases.

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

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

Range 3

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

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

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March 2002

SECTION 6

REPLACEMENT PARTS

WARNING

PARTS INTEGRITY

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

6-1 MATRIX

Each analyzer is configured per the customer sales order. Below is the CAT7 sales matrix which lists the various configurations available.

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

CAT7 CAT7 THERMAL CONDUCTIVITY ANALYZER

Code Parameter And Background Gas

10 Hydrogen in Air 11 Hydrogen in Nitrogen 12 Hydrogen in Methane 13 Hydrogen in Argon 14 Hydrogen in Carbon Dioxide 20 Helium in Air 21 Helium in Nitrogen 22 Helium in Oxygen 23 Helium in Methane 24 Helium in Argon 25 Helium in Carbon Dioxide 26 Helium in Argon & Oxygen 90 Argon in Air 91 Argon in Nitrogen 92 Argon in Oxygen 93 Carbon Dioxide in Air 94 Carbon Dioxide in Nitrogen 95 Carbon Dioxide in Oxygen 96 Nitrogen in Argon 50 Nitrogen in Hydrogen (0-5000 ppm Range Only. Range Code 31 60 Refinery (15% Hydrocarbon – 85% N2; 100% N2; 1% Hydrogen in 99% N2). Range Code 60 61 Utilities (BD Special) (80-100% H2 in Air, 0-100% H2 in CO2 and 0-100% Air in CO2). Range Code 61 97 Corrosive Gas Mixture Application (Zero Based Ranges Only). Range Code 97 98 Corrosive Gas Mixture Application (Suppressed Range Only). Range Code 98 99 Special

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Code Range

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

Code Single and Dual Range Analyzer

01 One Range, Voltage Output 02 One Range, Linearized Voltage Output 03 One Range with 4-20 mA Isolated Current Output 04 One Range, Linearized with 4-20 mA Isolated Current Output 05 Two Ranges, Voltage Output 06 Two Ranges, Range One Linearized Voltage Output 07 Two Ranges, Both Linearized Voltage Output 08 Two Ranges with 4-20 mA Isolated Current Output 09 Two Ranges, Range One Linearized Output; Both Ranges 4-20 mA Output 99 Triple Range

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

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Code Dual Range Analyzer; Second Range

Code Power, Alarm, Tropicalization

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

CAT7 11 03 02 17 04 Example

6-2 CIRCUIT BOARD REPLACEMENT POLICY

In most situations involving a malfunction of a circuit board, it is more practical to replace the board than to attempt isolation and replacement of the individual component. The cost of test and replacement will exceed the cost of a rebuilt assembly from the factory.

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

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

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6-3 REPLACEMENT PARTS

The following parts are recommended for routine maintenance and troubleshooting of the Model CAT7 Analyzer. If the troubleshooting procedures do not resolve the problem, contact Rosemount Analytical Customer Service Center (Section 7).

661540 Temperature Control Assembly 624006 Temperature Control Board 901913 Alarm Module 613560 Bridge Power Supply 619714

654632

654630

654628

654627

654631

654629

902444 902443 902442

±15V Power Supply Detector Assembly w/Filaments Flowing Ref (Gold Sheathed Tungsten) Detector Assembly w/Filaments Flowing Ref (Hytempco) Detector Assembly w/Filaments Flowing Ref (Tungsten) Detector Assembly w/Filaments Sealed Ref (Tungsten) Detector Assembly w/Filaments Sealed Ref Nitrogen (Gold Sheathed Tungsten) Detector Assembly w/Filaments Sealed Ref Nitrogen (Hytempco) Filaments (Gold Sheathed Tungsten) Filaments (Hytempco)

Filaments (Tungsten) 801566 Fuse 1.5A (230VAC) 000516 Fuse 3A (115VAC) 652816 Isolated Current Output Board 616443 Linearizer Kit (Factory Installed option. Consult factory.) 654620 Master Board 633875 Meter

Model CAT7

Sealed reference cells must be serviced at factory.

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

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SECTION 7

RETURN OF MATERIAL

7-1 RETURN OF MATERIAL

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

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

Rosemount CSC (Customer Service Center) will provide the shipping address for your instrument.

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

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

3. In a cover letter, describe completely:

• The symptoms that determined the

equipment is faulty.

• The environment in which the equip-

ment was operating (housing, weather, vibration, dust, etc.).

• Site from where the equipment was

removed.

• Whether warranty or non-warranty

service is expected.

• Complete shipping instructions for the

return of the equipment.

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

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

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

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

7-2 CUSTOMER SERVICE

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

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

7-3 TRAINING

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

Rosemount Analytical Inc.

Phone: 1-714-986-7600

FAX: 1-714-577-8006

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

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

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WARRANTY

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

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

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

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

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

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Emerson Process Management

Rosemount Analytical Inc. Process Analytic Division

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

ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd.

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

http://www.processanalytic.com

Fisher-Rosemount GmbH & Co.

Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd.

Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354

LATIN AMERICA Fisher - Rosemount

Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882

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Rosemount CAT 7 Thermal Conductivity Transmitter-Rev B Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF TABLES

PREFACE

DEFINITIONS

SAFETY SUMMARY

DOCUMENTATION

COMPLIANCES

DESCRIPTION AND SPECIFICATIONS

1-2 THERMAL CONDUCTIVITY CELL

1-1 ANALYZER MODULE

1-3 ELECTRONIC CIRCUITRY

1-4 GAS SELECTOR PANEL

1-5 SPECIFICATIONS

INSTALLATION

2-1 SITE PREPARATION

2-2 CUSTOMER ELECTRICAL CONNECTIONS

2-3 FLOW DIAGRAMS

2-4 LOCATION AND MOUNTING

a. Location

b. Mounting

2-5 UNPACKING

2-6 GAS REQUIREMENTS

2-7 CALIBRATION GAS REQUIREMENTS

a. Sample Gas Composition

2-9 LEAK CHECK

2-8 SUPPRESSED-ZERO RANGES

2-10 GAS CONNECTIONS

c. Isolated 4 to 20 mA Current Output

Alarm 1 Relay

Alarm 2 Relay

Fail-safe Applications

2-15 ELECTRICAL POWER CONNECTIONS

OPERATION

3-2 GAS SELECTOR PANEL CONTROLS

3-3 STARTUP PROCEDURE

3-4 CALIBRATION

THEORY

Sample Side

Reference Side

4-2 MASTER BOARD

a. Functions Associated with AR1

b. Coarse zero and zero-suppression

c. Functions Associated with AR2

d. Meter

e. Output Selection Switch S1

4-3 VOLTAGE OUTPUT LINEARIZER BOARD

4-5 BRIDGE POWER SUPPLY

4-7 DETECTOR BLOCKS

SERVICE AND MAINTENANCE

5-1 THERMAL CONDUCTIVITY CELL

5-2 ELECTRONIC CIRCUITRY

a. Amplifier Zero Adjustments

c. Case Temperature Controller

5-3 SUPPRESSED ZERO ADJUSTMENT

REPLACEMENT PARTS

6-1 MATRIX

6-3 REPLACEMENT PARTS

RETURN OF MATERIAL

7-1 RETURN OF MATERIAL

7-2 CUSTOMER SERVICE

7-3 TRAINING

WARRANTY