Rosemount Manual: 1000A GC Hardware Reference 3-9000-750 Rev A | Rosemount Manuals & Guides
Model 1000A
Gas Chromatograph
Hardware Reference Manual
Applies to Both
Daniel Danalyzer Model 1000A
Rosemount Analytical Model 1000A
Part Number 3-9000-750
Revision A
JUNE 2008
Model 1000A Gas Chromatograph
Hardware Reference Manual
NOTICE
DANIEL MEASUREMENT AND CONTROL, INC. AND ROSEMOUNT ANALYTICAL, INC.
(COLLECTIVELY, “SELLER”) SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS IN
THIS MANUAL OR OMISSIONS FROM THIS MANUAL. SELLER MAKES NO WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND, IN NO EVENT,
SHALL SELLER BE LIABLE FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING,
BUT NOT LIMITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, ETC.
PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER IDENTIFICATION
ONLY AND MAY BE TRADEMARKS/REGISTERED TRADEMARKS OF THESE COMPANIES.
THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORMATIONAL PURPOSES
ONLY, AND WHILE EVERY EFFORT HAS BEEN MADE TO ENSURE THEIR ACCURACY, THEY
ARE NOT TO BE CONSTRUED AS WARRANTIES OR GUARANTEES, EXPRESSED OR IMPLIED,
REGARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR
APPLICABILITY. WE RESERVE THE RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR
SPECIFICATIONS OF SUCH PRODUCTS AT ANY TIME.
SELLER DOES NOT ASSUME RESPONSIBILITY FOR THE SELECTION, USE OR MAINTENANCE
OF ANY PRODUCT. RESPONSIBILITY FOR PROPER SELECTION, USE AND MAINTENANCE OF
ANY SELLER PRODUCT REMAINS SOLELY WITH THE PURCHASER AND END-USER.
DANIEL AND THE DANIEL LOGO ARE REGISTERED TRADEMARKS OF DANIEL INDUSTRIES,
INC. THE ROSEMOUNT AND ROSEMOUNT ANALYTICAL LOGO THE ARE REGISTERED
TRADEMARKS OF ROSEMOUNT ANALYTICAL, INC. THE EMERSON LOGO IS A TRADEMARK
AND SERVICE MARK OF EMERSON ELECTRIC CO.
COPYRIGHT
All rights reserved. No part of this work may be reproduced or copied in any form or by any
means - graphic, electronic, or mechanical — without first receiving the written permission of
©
2008 BY DANIEL MEASUREMENT AND CONTROL, INC., HOUSTON, TEXAS,
U.S.A.
Daniel Measurement and Control, Inc. Houston, Texas, U.S.A.
WARRANTY
1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as
otherwise expressly provided herein, Daniel Measurement and Control, Inc. and Rosemount
Analytical, Inc., (collectively“Seller”) warrants that the firmware will execute the programming
instructions provided by Seller, and that the Goods manufactured or Services provided by Seller
will be free from defects in materials or workmanship under normal use and care until the
expiration of the applicable warranty period. Goods are warranted for twelve (12) months from
the date of initial installation or eighteen (18) months from the date of shipment by Seller,
whichever period expires first. Consumables and Services are warranted for a period of 90 days
from the date of shipment or completion of the Services. Products purchased by Seller from a
third party for resale to Buyer ("Resale Products") shall carry only the warranty extended by the
original manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond making
a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If
Buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable
warranty period, Seller shall, at its option, promptly correct any errors that are found by Seller in
the firmware or Services, or repair or replace F.O.B. point of manufacture that portion of the
Goods or firmware found by Seller to be defective, or refund the purchase price of the defective
portion of the Goods/Services. All replacements or repairs necessitated by inadequate
maintenance, normal wear and usage, unsuitable power sources, unsuitable environmental
conditions, accident, misuse, improper installation, modification, repair, storage or handling, or
any other cause not the fault of Seller are not covered by this limited warranty, and shall be at
Buyer's expense. Seller shall not be obligated to pay any costs or charges incurred by Buyer or
any other party except as may be agreed upon in writing in advance by an authorized Seller representative. All costs of dismantling, reinstallation and freight and the time and expenses of
Seller's personnel for site travel and diagnosis under this warranty clause shall be borne by Buyer
unless accepted in writing by Seller. Goods repaired and parts replaced during the warranty
period shall be in warranty for the remainder of the original warranty period or ninety (90) days,
whichever is longer. This limited warranty is the only warranty made by Seller and can be
amended only in a writing signed by an authorized representative of Seller. Except as otherwise
expressly provided in the Agreement, THERE ARE NO REPRESENTATIONS OR WARRANTIES OF
ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR
PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. It
is understood that corrosion or erosion of materials is not covered by our guarantee.
2.
LIMITATION OF REMEDY AND LIABILITY: SELLER SHALL NOT BE LIABLE FOR DAMAGES
CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF
WARRANTY HEREUNDER SHALL BE LIMITED TO REPAIR, CORRECTION, REPLACEMENT OR
REFUND OF PURCHASE PRICE UNDER THE LIMITED WARRANTY CLAUSE IN SECTION 1
HEREIN. IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION
(WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER
TORT OR OTHERWISE), SHALL SELLER'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS
EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED OR SERVICES
PROVIDED BY SELLER GIVING RISE TO THE CLAIM OR CAUSE OF ACTION. BUYER AGREES
THAT IN NO EVENT SHALL SELLER'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXTEND
TO INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. THE TERM
"CONSEQUENTIAL DAMAGES" SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF
ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE AND COST OF CAPITAL.
IMPORTANT INSTRUCTIONS
• Read all instructions prior to installing, operating, and servicing this product.
• Follow all warnings, cautions, and instructions marked on and supplied with this product.
• Inspect the equipment packing case and if damage exists, notify your local carrier for
liability.
• Open the packing list and carefully remove equipment and spare or replacement parts
from the case. Inspect all equipment for damage and missing parts.
• If items are missing, contact your local Product Services Department representative or
the sales office. Provide the equipment serial number and sales order number to the
Product Services Department or sales representative.
All returned equipment or parts must have an RMA (Returned Materials Authorization)
form obtained from the Products Services Department. Complete the Customer Problem
Report or include a letter describing the problem and corrective action to be performed at
the factory.
Phone: 1 (713) 827-5033
• Physically attach the RMA, corrective action documentation, and a copy of the packing
list to the equipment and place inside the shipping case. An envelope with a copy of the
packing list may be attached to the outside of the shipping case. Send to the address
shown above.
• Install equipment as specified per the installation instructions and per applicable local and
national codes. All connections shall be made to proper electrical and pressure sources.
• Ensure that all equipment doors are closed and protective covers are in place, except
when maintenance is being performed by qualified persons, to prevent personal injury.
• Use of this product for any purpose other than its intended purpose may result in property
damage and/or serious injury or death.
• Before opening the flameproof enclosure in a flammable atmosphere, the electrical
circuits must be interrupted.
• Repairs must be performed using only authorized replacement parts as specified by the
manufacturer. Use of unauthorized parts can affect the product's performance and place
the safe operation of the product at risk.
• When installing or servicing ATEX certified units, the ATEX approval applies only to
equipment without cable glands. When mounting the flameproof enclosures in a
hazardous area, only flameproof cable glands certified to IEC 60079-1 must be used.
This page is intentionally left blank.
Model 1000A
DESCRIPTION 1.1 PURPOSE OF THIS MANUAL ..........................1-1
TABLE OF CONTENTS i
TABLE OF CONTENTS
1.2 INTRODUCTION............................................1-2
1.3 FUNCTIONAL DESCRIPTION...........................1-3
1.4 MINIMUM PC REQUIREMENTS .......................1-5
1.5 MODES OF OPERATION.................................1-6
1.5.1 User Interface ...............................................1-6
1.5.2 Capabilities...................................................1-7
1.6 THEORY OF OPERATION ...............................1-8
EQUIPMENT
DESCRIPTION
1.6.1 Analyzer Detector .........................................1-8
1.6.2 Data Acquisition .........................................1-10
1.6.3 Peak Detection ...........................................1-11
1.6.4 Basic Analysis Computations ........................ 1-13
1.7 GLOSSARY ................................................1-16
2.1 SAMPLING SYSTEM......................................2-1
2.1.1 Sampling Point Location.................................2-2
2.1.2 Sample Volume and Flow Rate........................2-2
2.1.3 Sample Conditioning......................................2-3
2.1.4 Contamination Precautions .............................2-3
2.1.5 Valving ........................................................2-3
2.1.6 Calibration Gas .............................................2-3
2.2 ANALYZER...................................................2-4
2.2.1 Physical Description ......................................2-4
2.2.2 Chromatograph Valves...................................2-5
2.2.3 Detector Subsystem ......................................2-6
MAY 2008 DESCRIPTION
ii TABLE OF CONTENTS
Model 1000A
2.2.4 Analyzer Preamplifier Unit ..............................2-6
2.2.5 Analyzer Specifications ..................................2-7
2.2.6 Utility Gas Requirements ................................2-8
2.3 ELECTRONIC ASSEMBLY ...............................2-8
2.3.1 Controller Hardware Configurations ................. 2-8
INSTALLATION AND
SETUP
3.1 PRECAUTIONS AND WARNINGS .................... 3-3
3.1.1 Hazardous Environments ................................3-3
3.1.2 Power Source Wiring .....................................3-4
3.1.3 Signal Wiring ................................................3-5
3.1.4 Electrical and Signal Ground ...........................3-6
3.1.5 Electrical Conduit ..........................................3-8
3.1.6 Sample Systems Requirements .......................3-9
3.2 PREPARATION............................................ 3-10
3.2.1 Introduction................................................ 3-10
3.2.2 Site Selection .............................................3-10
3.2.3 Unpacking the Unit...................................... 3-11
3.2.4 Necessary Tools and Components ................. 3-12
3.2.5 Optional Tools and Components.................... 3-13
3.3 INSTALLING THE ANALYZER .......................3-14
3.3.1 Analyzer AC Power Wiring ........................... 3-14
3.3.2 Sample and Gas Lines.................................. 3-15
3.4 SETTING THE COM ID ................................. 3-18
3.4.1 Inspect or Change the Com ID ...................... 3-18
3.4.2 Preparing for Serial Connections.................... 3-22
3.4.3 FTB Connection (RS-232)............................. 3-24
3.4.4 PC to GC Cable Short Distance Connection
(RS-232) .................................................... 3-25
3.4.5 Long Distance Connection (RS-422, RS-485).. 3-32
INSTALLATION AND SETUP MAY 2008
Model 1000A
TABLE OF CONTENTS iii
3.4.6 Ethernet Connection (Optional) ....................3-33
3.4.7 GC-Printer Wiring ........................................ 3-34
3.4.8 Discrete Digital I/O Wiring ............................3-35
3.4.9 Analog Input Wiring.....................................3-38
3.4.10 Analog Output Wiring .................................. 3-39
3.4.11 Optional Boards ..........................................3-41
3.5 ANALYZER LEAK CHECKS AND PURGING FOR
FIRST CALIBRATION ...................................3-43
3.5.1 Analyzer Leak Checks.................................. 3-43
3.5.2 Purging Carrier Gas Lines ............................. 3-44
3.5.3 Purging Calibration Gas Lines........................3-46
3.6 SYSTEM START-UP ....................................3-47
MAINTENANCE AND
TROUBLESHOOTING
4.1 HAZARDOUS ENVIRONMENTS.......................4-1
4.2 TROUBLESHOOTING AND REPAIR CONCEPT ...4-2
4.3 ROUTINE MAINTENANCE...............................4-2
4.3.1 Bimonthly Maintenance Checklist ....................4-2
4.3.2 Routine Maintenance Procedures.....................4-4
4.3.3 Contact Service ............................................4-4
4.4 ACCESS TO GC EQUIPMENT ELEMENTS .........4-4
4.4.1 Electrical/Electronic Components.....................4-4
4.4.2 Detector Elements, Heater Elements, Valves and
Columns ......................................................4-7
4.5 PRECAUTIONS FOR HANDLING PC
ASSEMBLIES ................................................4-9
4.6 GENERAL TROUBLESHOOTING.......................4-9
4.6.1 Hardware Alarms ..........................................4-9
4.6.2 Troubleshooting Checklist ............................ 4-12
4.6.3 Test Points Dual Methods Board and FTB .......4-15
MAY 2008 MAINTENANCE AND TROUBLESHOOTING
iv TABLE OF CONTENTS
Model 1000A
4.6.4 Preamplifier ................................................ 4-17
4.6.5 Flow Balance Check .................................... 4-17
4.6.6 Temperature............................................... 4-17
4.6.7 FID Configuration ........................................4-19
4.7 LEAK CHECKS............................................ 4-20
4.7.1 Field Service............................................... 4-20
4.7.2 Factory Level Leak Check............................. 4-21
4.7.3 Plugged Lines, Columns, or Valves ................ 4-23
4.8 CHROMATOGRAPH VALVES........................ 4-24
4.8.1 Required Tools............................................ 4-24
4.8.2 Chromatograph Valve Replacement Parts ....... 4-24
4.8.3 Valve Cleaning............................................4-25
4.8.4 Valve Overhaul ...........................................4-25
4.8.5 TCD Replacement ....................................... 4-27
4.8.6 Micro-FID Removal ...................................... 4-29
4.8.7 Micro-FID Maintenance ................................ 4-31
4.8.8 Micro-FID Re-assembly ................................4-32
4.9 TCD DETECTOR BRIDGE BALANCE............... 4-32
4.10 MEASURE VENT FLOW ...............................4-35
4.11 MODEL 1000A ELECTRICAL COMPONENTS ..4-36
4.11.1 DC Power Supply Replacement Procedures..... 4-39
4.12 COMMUNICATIONS ....................................4-40
4.13 ANALOG INPUTS/OUTPUTS......................... 4-43
4.13.1 Model 1000A Analog Inputs......................... 4-44
4.13.2 Analog Output Adjustment ...........................4-45
4.13.3 Model 1000A Analog Outputs ...................... 4-46
4.14 DISCRETE DIGITAL INPUTS/OUTPUTS ..........4-48
MAINTENANCE AND TROUBLESHOOTING MAY 2008
Model 1000A
TABLE OF CONTENTS v
4.15 RECOMMENDED SPARE PARTS.................... 4-49
4.16 UPGRADE PROCEDURES .............................4-49
4.16.1 Base Operating System ................................4-49
4.16.2 Applications ...............................................4-49
RECOMMENDED SPARE
PARTS
APPENDIX A,
COMMUNICATIONS
SPECIFICATIONS
5.1 ANALYZER SPARES ......................................5-2
5.1.1 Printed Circuit Card Assemblies (Analyzer) .......5-2
5.1.2 Electrical and Mechanical Assemblies (Analyzer)5-2
A.1 TCD SERIAL COMMUNICATIONS................... A-1
A.1.1 Model 1000A with TCD Communications Ports A-2
A.2 FID SERIAL COMMUNICATIONS .................... A-5
A.2.1 Connecting Serial Communications to the GC .. A-8
A.2.2 FTB Serial Communications ..........................A-10
A.3 WIRING LOCAL RS-232 COMMUNICATIONS..A-21
A.3.1 GC Serial Port and Cable Configurations.........A-21
A.3.2 GC DB 9-pin Serial Port to PC DB 9-pin Port ...A-24
A.3.3 GC DB 9-pin Serial Port to PC DB 25-pin Port .A-25
A.3.4 GC PHOENIX Plug Port to PC DB 9-pin Port ....A-26
A.3.5 GC PHOENIX Plug Port to PC DB 25-pin Port ..A-27
A.4 WIRING REMOTE RS-232
COMMUNICATIONS ....................................A-28
A.4.1 GC DB 9-pin Serial Port to Modem DB 25-pin
Port...........................................................A-28
A.4.2 GC PHOENIX Plug to Modem DB 25-pin Port ..A-29
A.5 EXAMPLE RS-422 PC-GC CONNECTION ........A-30
A.6 EXAMPLE RS-485 PC-GC CONNECTION ........A-32
MAY 2008 RECOMMENDED SPARE PARTS
vi TABLE OF CONTENTS
Model 1000A
APPENDIX B, MODEM
INSTALLATION
APPENDIX C,
MANIFOLD CARRIER
FOR GAS BOTTLES
APPENDIX D, LOCAL
OPERATOR INTERFACE
B.1 OPTIONAL INTERNAL MODEM .......................B-1
B.1.1 Optional Ethernet Board ................................. B-3
C.1 CARRIER GAS ..............................................C-1
C.2 INSTALLATION AND LINE PURGING................C-2
C.3 REPLACING CARRIER CYLINDER ....................C-3
C.4 CALIBRATION GAS .......................................C-3
D.1 INTERFACE COMPONENTS FOR DISPLAYING AND
ENTERING DATA ..........................................D-1
D.1.1 Light Emitting Diode Indicators........................D-1
D.1.2 LCD Screen ..................................................D-2
D.1.3 Keypad ........................................................D-2
D.1.4 Security Switch ............................................D-2
D.2 USING THE LOCAL OPERATOR INTERFACE .....D-3
APPENDIX E,
ENGINEERING
DRAWINGS
D.2.1 Navigating the Screen....................................D-4
D.2.2 Editing Numeric Data .....................................D-4
D.2.3 Editing Non-Numeric Data ..............................D-5
D.3 NAVIGATING THE LOI MENUS .......................D-7
D.3.1 The Ctrl Menu ..............................................D-9
D.3.2 The App Menu............................................D-14
D.3.3 The Chrom Menu ........................................D-23
D.3.4 The Logs Menu ...........................................D-29
D.3.5 The Manage Menu ......................................D-37
E.1 LIST OF ENGINEERING DRAWINGS ................. E-1
APPENDIX B, MODEM INSTALLATION MAY 2008
Model 1000A
DESCRIPTION
1.1 PURPOSE OF THIS MANUAL
The Emerson Process Management Model 1000A Gas Chromatograph
System Hardware Reference Manual (P/N 3-9000-750) is intended as a
user's guide to accompany the MODEL 1000A GAS CHROMATOGRAPH
SYSTEM.
NOTE: For software operation instructions, see the MON2000
Software for Gas Chromatographs User Manual (P/N 3-9000-522).
This manual provides the following information:
• A general description of the Model 1000A Gas Chromatograph (GC)
System and its components, their configurations and functions.
(Section 1: Description)
DESCRIPTION 1-1
• A brief description of the GC System's software, user interfaces, and
capabilities. (Section 1: Description)
• Introduction to GC theory of operation and terminology. (Section 1:
Description)
• Guidelines for sampling system and gas connections. (Section 2:
Equipment Description)
• Descriptions of Analyzer subsystems and components. (Section 2:
Equipment Description)
• Descriptions of GC Controller subsystems and components. (Section 2:
Equipment Description)
• Instructions for installing the GC System hardware. (Section 3:
Installation and Startup)
• Instructions for regular maintenance and care of the GC System
hardware. (Section 4: Maintenance)
• Instructions for troubleshooting, repair, and service of the GC System
hardware. (Section 4: Maintenance)
• List of boards, valves, and other components suggested as spare parts.
(Section 5: Recommended Spare Parts)
JUNE 2008 PURPOSE OF THIS MANUAL
1-2 DESCRIPTION
• Appendices with additional, helpful reference materials and drawings.
(Appendices)
1.2 INTRODUCTION
The Emerson Process Management Model 1000A Gas Chromatograph is
a high-speed GC system that is factory engineered to meet specific field
application requirements based on stream composition and the
anticipated concentration of the components of interest. The GC system
typically consists of two major components, the Analyzer Assembly and
the Sample Conditioning System:
• Analyzer Assembly (Model 1000A Series)
Located near the sample tap in a freeze-protected shelter. The
Analyzer includes columns, detectors, preamplifier, stream switching
valves, solenoids, and the GC, which includes electronics and ports for
signal processing, instrument control, data storage, personal
computer (PC) interface, and telecommunications.
Model 1000A
• Sample Conditioning System (SCS)
Located between the process stream and the Analyzer sample inlet,
usually mounted on the lower portion of the Analyzer stand. The
standard configuration SCS includes a mounting plate, block (or
shutoff) valves, and filters. Optionally, the SCS can be configured with
Genie® bypass filters, liquid shut-off valves, and optional solenoids for
stream switching; all of which can be enclosed in an electric (heat tape
design) oven.
In its standard configuration, the Model 1000A series Analyzer can
handle up to five streams: typically, four for sample and one for
calibration. With an optional stream switch assembly added, the GC can
switch up to twelve streams, maximum.
Although the GC is designed to be operated primarily from the LOI, you
can also use a personal computer (PC) running MON2000. The PC option
provides the user with the greatest capability, ease-of-use, and flexibility.
One PC running MON2000 can connect with up to 32 chromatographs
(via RS-485 serial communications links). The PC is used to display
analysis chromatograms and reports, which can then be stored to files on
the PC hard drive, or printed from either the PC's printer port or the GC's
printer port.
INTRODUCTION JUNE 2008
Model 1000A
Since neither the PC nor a normal printer can be placed in a hazardous
area, serial port and Modbus communications links are provided for
connecting the GC to the PC, other computers, printers, and controllers.
1.3 FUNCTIONAL DESCRIPTION
A functional block diagram of a typical GC installation is shown in Figure
1-1. A sample of the gas to be analyzed is taken from the process stream
by a sample probe installed in the process line. The sample passes
through a sample line to the sample conditioning system where it is
filtered or otherwise conditioned. After conditioning, the sample flows to
the Analyzer for separation and detection of the components of the gas.
The chromatographic separation of the sample gas into its components is
accomplished in the Analyzer in the following manner. A precise volume
of sample gas is injected into one of the unit's analytical columns. The
column contains a stationary phase (packing) that is either an active solid
(adsorption partitioning) or an inert solid support that is coated with a
liquid phase (absorption partitioning). The gas sample is moved through
the column by means of a mobile phase (carrier gas). Selective
retardation of the components of the sample takes place in the column
that causes each component to move through the column at a different
rate. This action separates the sample into its constituent components.
DESCRIPTION 1-3
A detector located at the outlet of the analytical column senses the
elution of components from the column and produces electrical outputs
proportional to the concentration of each component. Outputs from the
Analyzer detectors are amplified in the Analyzer electronics, then
transmitted to the GC for further processing. See Section 1.6 for more
information.
Although output from the GC is normally displayed on the LOI, it can
also be displayed on a remotely located personal computer or a printer.
Connection between the GC and the PC can be accomplished via a direct
serial line or via the Modbus-compatible communication interface.
Multiple chromatograms may be displayed on the LOI and compared or
contrasted with separate color schemes. This allows a stored
chromatogram to be compared/contrasted with a current or another
stored chromatogram. This could be of great assistance when changing
parameters or isolating a problem.
JUNE 2008 FUNCTIONAL DESCRIPTION
1-4 DESCRIPTION
Model 1000A
In most instances, it is essential to use a PC for detailed troubleshooting
procedures. Basic operations should be performed from the LOI that is
built into the Model 1000A. With optional electronic boards, the PC can
be connected remotely via ethernet, telephone, radio or satellite. Once
installed and configured, the GC can operate independently for long
periods of time.
Figure 1-1 GC System Functional Block Diagram
FUNCTIONAL DESCRIPTION JUNE 2008
Model 1000A
1.4 MINIMUM PC REQUIREMENTS
To achieve maximum performance when running the MON2000 software,
ensure your PC system contains the following hardware and software
equipment.
• PC with a 486/90 MHz or higher processor (Pentium/100MHz or
higher recommended) running:
- Windows® 95 (service pack 1 or better) or later
NOTE: If running Windows® 95 with the optional ethernet card, the
user must download Socket 2 from www.microsoft.com/windows95/
downloads to utilize MON2000’s ethernet feature.
- Windows® 98 version 1 or later
DESCRIPTION 1-5
- Windows® 2000 version 1 or later
- Windows® XP version 1 or later (see note for system requirements)
- Windows® Vista version 1 or later
NOTE: You must have administrator privileges to intall MON2000
because Vista will not allow a ‘standard’ user to install software.
Even with administrator privileges, you will be prompted by Vista’s
User Account Control feature to allow or cancel the installation. For
more details, refer to Getting Started with User Account Control on
Windows Vista (http://go.microsoft.com/fwlink/?LinkID=102562).
- Windows® NT version 4 (service pack 3 or later)
• 16 MB of RAM (32 MB or higher recommended)
• 5 MB of free hard disk space
• Super VGA monitor with 800x600 resolution
• Free serial port for remote/local connection to gas chromatograph (for
online operations)
• Free parallel port for connection to printer
• Windows®-compatible modem (for remote connection only)
JUNE 2008 MINIMUM PC REQUIREMENTS
1-6 DESCRIPTION
NOTE: Microsoft Internet Explorer 5.0 is required to view
spreadsheets or reports saved in HTML format.
•Use the Settings → Control Panel → System → General Page menu
path to check the system version number.
- For Windows® 95, the version number should be 4.00.950A/B or
later.
- For Windows® 98 or Windows® 2000, the version number should
be 1 or later.
- To use Windows® XP you need a PC with 300 MHz or higher
processor clock speed recommended; 233 MHz minimum required
(single or dual processor system);* Intel® Pentium®/Celeron®
family, or AMD K6®/Athlon™/Duron™ family, or compatible
processor recommended.
- Memory 128 MB of RAM or higher recommended (64 MB minimum
supported; may limit performance and some features)
Model 1000A
- Hard Disk Minimum: 1.5 GB of available hard disk space
- For Windows NT4, the version number should be 4.00.1381 or
later.
1.5 MODES OF OPERATION
1.5.1 User Interface
You have two user interfaces from which to operate the gas
chromatograph (GC) system: the LOI or a PC connected to the GC and
running MON2000.
The LOI allows you to gather basic information and to perform
maintenance repairs at the GC site.
A PC connected to the GC and running MON2000 offers the greatest
amount of capability and flexibility.
Find complete user instructions for MON2000 in the program’s online
HELP manual as well as in the MON2000 Software for Gas
Chromatographs User Manual (P/N 3-9000-522).
MODES OF OPERATION JUNE 2008
Model 1000A
1.5.2 Capabilities
Some of the individual GC controller functions that can be initiated or
controlled by the GC and its software, MON2000, include the following:
• Valve activations
• Timing adjustments
• Stream sequences
• Heater controls (when applicable)
• Calibrations
• Baseline runs
•Analyses
• Halt operation
DESCRIPTION 1-7
• Stream/detector assignments
• Stream/component table assignments
• Stream/calculation assignments
•Diagnostics
• Alarm and event processing
• Event sequence changes
• Component table adjustments
• Calculation adjustments
• Alarm parameters adjustments
• Analog scale adjustments
Some of the reports and logs that can be produced, depending upon the
GC application in use, include the following:
• Configuration report
• Parameter list
• Analysis chromatogram
• Chromatogram comparison
JUNE 2008 Capabilities
1-8 DESCRIPTION
• Alarm log (unacknowledged and active)
•Event log
• Analysis raw data
1.6 THEORY OF OPERATION
NOTE: See Section 1.7 for definitions of some of the terminology used
in the following explanations.
1.6.1 Analyzer Detector
The Analyzer detector subsystem is a thermal conductivity detector that
consists of a balanced bridge network with heat-sensitive thermistors in
each leg of the bridge. Each thermistor is enclosed in a separate chamber
of the detector block. One thermistor is designated the reference element
and the other the measurement element. A schematic diagram of the
thermal conductivity detector is shown in Figure 1-2.
Model 1000A
THEORY OF OPERATION JUNE 2008
Model 1000A
In the quiescent condition (prior to injecting a sample), both legs of the
bridge are exposed to pure carrier gas. In this condition, the bridge is
balanced and the bridge output is electrically nulled. The bridge can be
balanced by the fine and coarse adjustment potentiometers located on the
preamplifier circuit board.
The analysis begins when a fixed volume of sample is injected into the
column by operation of the sample valve. The sample is moved through
the column by the continuous flow of carrier gas. As successive
components elute from the column, the temperature of the measurement
element changes. The temperature change unbalances the bridge and
produces an electrical output proportional to the component
concentration. The differential signal developed between the two
thermistors is amplified by the preamplifier.
DESCRIPTION 1-9
Figure 1-2 Schematic Diagram of Analyzer Detector Bridge
Figure 1-3 illustrates the change in detector electrical output during
elution of a component.
3
1
detector bridge balanced
1
component begins to elute from column
2
and is measured by thermistor
peak concentration of component
3
Figure 1-3 Detector output during component elution
2
1
JUNE 2008 Analyzer Detector
1-10 DESCRIPTION
In addition to amplifying the differential signal developed between the
detector's two thermistors, the preamplifier also supplies drive current to
the detector bridge. The preamplifier also supplies drive current to the
detector bridge. The voltage signal is converted to a 4 to 20-milliamp
(mA) current loop for transmission to the GC Controller.
The signal is proportional to the concentration of a component detected in
the gas sample. The preamplifier provides four different gain channels as
well as compensation for baseline drift.
The signals from the preamplifier are sent to the GC Controller for
computation, recording on a printer, or viewing on a PC monitor or LOI.
1.6.2 Data Acquisition
Every second, exactly 40 equi-spaced data samples are taken for analysis
by the GC (i.e., once every 25 milliseconds). Each data sample, after
having been precision-amplified, is subjected to a twelve bit analog to
digital (A/D) conversion. The sampling frequency of 40 Hertz (Hz) was
chosen to reduce 60 Hz normal mode noise.
Model 1000A
After each point on the chromatograph signal is sampled, the resulting
number is stored in a buffer area in the GC’s memory for processing.
During the analysis, only the last 256 data points are available for
processing. Because the data analysis is done as the signal is sampled (in
real-time), only a limited number of past data samples is required to
analyze any signal.
As a part of the data acquisition process, groups of incoming data samples
are averaged together before the result is stored to the GC’s memory for
processing. Non-overlapping groups of N samples are averaged and
stored, and thus reduce the effective incoming data rate to 40/N samples/
second. For example, if N = 5, then a total of 40/5 or 6 (averaged) data
samples are stored every second. The value for the variable N is
determined by the selection of a Peak Width (PW) parameter. The
relationship is:
N PW ondssec=
Data Acquisition JUNE 2008
Model 1000A
where PW is given in seconds. All the various details in the analysis
process are independent of the value of N. Allowable values of N are 1 to
63, which corresponds to values of PW from 2 to 63 seconds.
The variable N is known as the integration factor. This term is used
because N determines how many points are averaged or integrated to
form a single value. The integration of data upon input, before storing,
serves two purposes. First, the statistical noise on the input signal is
reduced by the square root of N. In the case of N = 4, a noise reduction of
two would be realized. Secondly, the integration factor controls the
bandwidth of the chromatograph signal. It is necessary to match the
bandwidth of the input signal to that of the analysis algorithms in the
GC. This prevents small, short duration perturbations from being
recognized as true peaks by the program. It is therefore important to
choose a Peak Width corresponding to the narrowest peak in a group
under consideration.
DESCRIPTION 1-11
1.6.3 Peak Detection
For normal area or peak height concentration evaluation, the
determination of a peak's start, peak point, and end is automatic. The
manual determination of start and end points is used only for area
calculations in the Forced Integration mode. Automatic determination of
peak onset or start is initiated whenever Integrate Inhibit is turned off.
Analysis is started in a region of signal quiescence and stability, such
that the signal level and activity can be considered as baseline values. It
is important that this be the case because the assumption is made by the
GC software.
Having initiated a peak search by turning Inhibit off, the GC performs a
point by point examination of the signal slope. This is achieved by using
a digital slope detection filter which is a combination low pass filter and
differentiator. The output of this detector is constantly compared to a
system constant entered by the operator called Slope Sensitivity. A
default value of 8 is assumed if no entry is made. Lower values make
peak onset detection more sensitive, and higher values make detection
less sensitive. Higher values (20 to 100) would be appropriate for noisy
signals, e.g. high amplifier gain.
Peak termination is determined by the same application of this detector
to the signal, but in the reverse sense. Onset is defined where the
JUNE 2008 Peak Detection
1-12 DESCRIPTION
Model 1000A
detector output exceeds the baseline constant, but termination is defined
subsequently where the detector output is less than the same constant.
Sequences of fused peaks are also automatically handled. This is done by
testing each termination point to see if the region immediately following
it satisfies the criteria of a baseline. A baseline region must have a slope
detector value less than the magnitude of the baseline constant for a
number of sequential points. When a baseline region is found, this
terminates a sequence of peaks.
A zero reference line for peak height and area determination is
established by extending a line from the point of the onset of the peak
sequence to the point of the termination. The values of these two points
are found by averaging the four integrated points just prior to the onset
point and just after the termination points, respectively. The zero
reference line will, in general, be non-horizontal, and thus compensates
for any linear drift in the system from the time the peak sequence starts
until it ends.
In a single peak situation, peak area is the area of the component peak
between the curve and the zero reference line. The peak height is the
distance from the zero reference line to the maximum point on the
component curve. The value and location of the maximum point is
determined from quadratic interpolation through the three highest points
at the peak of the discrete valued curve stored in the GC.
For fused peak sequences, this interpolation technique is used both for
peaks as well as valleys (minimum points). In the latter case, lines are
dropped from the interpolated valley points to the zero reference line to
partition the fused peak areas into individual peaks. The use of
quadratic interpolation improves both area and height calculation
accuracy and eliminates the effects of variations in the integration factor
on these calculations.
For calibration, the GC may average several analyses of the calibration
stream.
Peak Detection JUNE 2008
Model 1000A
1.6.4 Basic Analysis Computations
Two basic analysis algorithms are included in the GC. These are:
• Area Analysis - Calculates area under component peak
• Peak Height Analysis - Measures height of component peak
Concentration Analysis by Using Response Factor
Concentration calculations require a unique response factor foreach
component in an analysis. These response factors may be manually
entered by an operator or determined automatically by the system
through calibration procedures (with a calibration gas mixture that has
known concentrations).
Response factor calculation: (using the external standard)
DESCRIPTION 1-13
or
where:
ARF
n
HRF
n
Area
n
Ht
n
Cal
n
Area
n
-------------- -
=
ARF
n
Cal
n
Ht
n
-----------
=
HRF
n
Cal
n
Area response factor for component n in area per mole percent (%).
Height response factor for component n.
Area associated with component n in calibration gas.
Height associated with component n in mole percent in calibration gas.
Amount of component n in mole percent in calibration gas.
Calculated response factors are stored by the GC for use in the
concentration calculations, and are printed out in the configuration and
calibration reports.
JUNE 2008 Basic Analysis Computations
1-14 DESCRIPTION
Average response factor is calculated as follows:
k
∑
i 1=
RFAVG
where:
RFAVGnArea or height average response factor for component n.
=
n
------------------
k
RF
Model 1000A
i
Rf
i
Area or height response factor for component n from the calibration run.
k Number of calibration runs actually used to calculate the response
factors.
The percent deviation of new RF averages from old RF average is
calculated in the following manner:
% deviation
new
------------------------------------- -
RF
old
old
100×=
RF
∠
RF
where the absolute value of % deviation for alarm has been previously
entered by the operator.
Concentration Calculations in Mole % without Normalization
Once response factors have been determined by the GC or entered by the
operator, component concentrations are determined for each analysis by
using the following equations:
Area
n
-------------- -
CONC
=
n
ARF
n
Basic Analysis Computations JUNE 2008
Model 1000A
or
where:
CONCnConcentration of component n in mole percent.
CONC
DESCRIPTION 1-15
Ht
n
--------------
=
n
HRF
n
Area
ARF
Area of component n in unknown sample
n
Response factor of component n calculated from area of calibration
n
sample. Units are area per mole percent.
Ht
n
HRF
Peak height of component n in unknown sample
Response factor of component n calculated from peak height of cal-
n
ibration sample. Units are height per mole percent.
Note that the average concentration of each component will also be
calculated when data averaging is requested.
Component concentrations may be input through analog inputs 1 - 4 or
may be fixed. If a fixed value is used, the calibration for that component
is the mole % that will be used for all analyses.
Concentration Calculations with Normalization
CONC
CONCN
n
----------------------------
∑
i 1=
k
CONC
n
100×=
i
where:
CONCN
CONC
CONC
k Number of components to be included in the normalization.
JUNE 2008 Basic Analysis Computations
Normalized concentration of component n in percent of total gas
n
concentration.
Non-normalized concentration of component n in mole percent.
n
Non-normalized concentration (in mole percent) from each of the k
i
components to be grouped into this normalization.
1-16 DESCRIPTION
NOTE: For additional information about other calculations that are
performed by the GC and software, see the MON2000 Software for
Gas Chromatographs User Manual (P/N 3-9000-522).
1.7 GLOSSARY
Auto Zero: Automatic zeroing of the preamplifier. May be entered into
the Controller to take place at any time during the analysis when either
the component is not eluting or the baseline is steady.
Chromatogram: A permanent record of the detector output. A
chromatograph is obtained from the LOI or from a PC interfaced with the
detector output through the GC. A typical chromatogram displays all
component peaks, and gain changes. It may be viewed in color as it is
processed on the LOI or a PC VGA display. Tick marks recorded on the
chromatogram by the GC indicate where timed events take place.
Model 1000A
Component: Any one of several different gases that may appear in a
sample mixture. For example, natural gas usually contains the following
components: nitrogen, carbon dioxide, methane, ethane, propane,
isobutane, normal butane, isopentane, normal pentane, and hexanes
plus.
Condulet: Fitting resembling a pipe or a box with a removable cover for
access to electric conduits.
CTS: Clear to send (a serial port pin assignment).
DCD: Data carrier detect; see also, RLSD (a serial port pin assignment).
DSR: Data set ready (a serial port pin assignment).
DTR: Data terminal ready (a serial port pin assignment).
LOI: Local operator interface; an integrated color display panel with
infrared touchkeys that allows you to interact with the GC.
Response Factor: Correction factor for each component as determined
by the calibration. See “Concentration Analysis by Using Response
Factor” on page 13 for more information.
GLOSSARY JUNE 2008
Model 1000A
Retention Time: The time (in seconds) that elapses between start of
analysis (0 seconds) and the sensing of the maximum concentration of
each component by the Analyzer detector.
RI: Ring indicator (a serial port pin assignment).
RLSD: Received line signal detect (a digital simulation of carrier detect);
see also, DCD (a serial port pin assignment).
RTS: Request to send (a serial port pin assignment).
RxD, RD, or SIN: Receive data, or signal in (a serial port pin
assignment).
DESCRIPTION 1-17
TxD, TD, or S
assignment).
: Transmit data, or signal out (a serial port pin
OUT
JUNE 2008 GLOSSARY
1-18 DESCRIPTION
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Model 1000A
GLOSSARY JUNE 2008
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