Rosemount Manual: 7D Thermal Conductivity Analyzer Explosion Proof-Rev M | Rosemount Manuals & Guides
Instruction Manual
748221-M
July 2002
Model 7D
Thermal Conductivity Analyzer
http://www.processanalytic.com
Emerson Process Management
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and
international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and integrated into your
safety program when installing, using, and maintaining Rosemount Analytical products. Failure to
follow the proper instructions may cause any one of the following situations to occur: Loss of life;
personal injury; property damage; damage to this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical representative
for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance of
the product.
• Install your equipment as specified in the Installation Instructions of the appropriate
Instruction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and
maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by
Rosemount. Unauthorized parts and procedures can affect the product’s performance, place the safe
operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result
in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when
maintenance is being performed by qualified persons, to prevent electrical shock and personal
injury.
The information contained in this document is subject to change without notice.
Teflon is a registered trademark of E.I. duPont de Nemours and Co., Inc.
SNOOP is a registered trademark of NUPRO Co.
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com
Model 7D
PREFACE................................................................................................................................ P-1
Definitions................................................................................................................................ P-1
Intended Use Statement ............................................................................................................P-2
Safety Summary....................................................................................................................... P-2
General Precautions For Handling And Storing High Pressure Gas Cylinders............................... P-4
Documentation .........................................................................................................................P-5
Compliances ............................................................................................................................ P-5
1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1
1-1 Overview...................................................................................................................... 1-1
1-2 Analyzer Module ...........................................................................................................1-1
1-3 Gas Selector Panel .......................................................................................................1-4
1-4 Specifications............................................................................................................... 1-5
Instruction Manual
748221-M
July 2002
TABLE OF CONTENTS
a. Thermal Conductivity Cell........................................................................................ 1-1
b. Electronic Circuitry ..................................................................................................1-3
2-0 INSTALLATION ...........................................................................................................2-1
2-1 Facility Preparation....................................................................................................... 2-1
a. Installation Drawings............................................................................................... 2-1
b. Customer Electrical Connections ............................................................................. 2-1
c. Flow Diagrams ....................................................................................................... 2-1
d. Location and Mounting ............................................................................................ 2-1
2-2 Unpacking.................................................................................................................... 2-1
2-3 Gas Requirements........................................................................................................ 2-1
a. General.................................................................................................................. 2-1
b. Calibration Gas Requirements .................................................................................2-1
c. Sample Gas Composition ........................................................................................2-1
d. Suppressed-Zero Ranges ....................................................................................... 2-2
2-4 Leak Check ..................................................................................................................2-3
2-5 Gas Connections.......................................................................................................... 2-3
2-6 Recorder Output Selection and Cable Connections .........................................................2-7
a. Standard (Non-linearized) Voltage Output ................................................................ 2-7
b. Linearized Voltage Output (Optional)....................................................................... 2-7
c. Isolated 4 to 20 mA Current Output (Optional) .......................................................... 2-7
d. Dual Alarms (Optional) ............................................................................................2-9
e. Linearized Voltage, Two Ranges (Optional) ..............................................................2-10
f. Linearized Voltage and Isolated 4 to 20 mA Current Output (Optional) ....................... 2-11
2-7 Electrical Power Connections ........................................................................................ 2-12
3-0 STARTUP AND OPERATION....................................................................................... 3-1
3-1 Analyzer Controls and Adjustments ............................................................................... 3-1
3-2 Gas Selector Panel Controls ......................................................................................... 3-1
3-3 Startup Procedure......................................................................................................... 3-1
3-4 Calibration.................................................................................................................... 3-2
3-5 Routine Operation......................................................................................................... 3-2
3-6 Recommended Calibration Frequency ........................................................................... 3-3
3-7 Shutdown..................................................................................................................... 3-3
Rosemount Analytical Inc. A Division of Emerson Process Management Contents i
Instruction Manual
748221-M
July 2002
4-0 THEORY...................................................................................................................... 4-1
4-1 Thermal Conductivity Cell and Associated Bridge Adj ustments........................................4-1
4-2 Electronic Circuitry ........................................................................................................4-1
a. Master Board.......................................................................................................... 4-1
b. Voltage Output Linearizer Board (Optional).............................................................. 4-2
c. Isolated 4 to 20 mA Current Output Board (Optional)................................................. 4-4
d. Bridge Power Supply .............................................................................................. 4-4
e. ±15 Volt Power Supply ............................................................................................4-4
f. Detector Blocks...................................................................................................... 4-4
g. Case Temperature Controller Assembly ...................................................................4-5
h. Dual Alarms (Option).............................................................................................. 4-5
5-0 SERVICE AND MAINTENANCE ................................................................................... 5-1
5-1 Thermal Conductivity Cell.............................................................................................. 5-1
5-2 Electronic Circuitry ........................................................................................................5-1
a. Amplifier Zero Adjustments ..................................................................................... 5-1
b. Bridge Balance and Range Sensitivity Adjustments .................................................. 5-2
c. Bridge Voltage Adjustment ...................................................................................... 5-2
d. Case Temperature Cont roller..................................................................................5-3
e. Dual Alarm Module (Optional).................................................................................. 5-3
5-3 Suppressed Zero Adjustment ........................................................................................ 5-3
Model 7D
6-0 REPLACEMENT PARTS ..............................................................................................6-1
6-1 Circuit Board Replacement Policy.................................................................................. 6-1
6-2 Replacement Parts....................................................................................................... 6-1
a. Selected Replacement Parts................................................................................... 6-2
b. Temperature Control Assembly ............................................................................... 6-2
c. Alarm Option ..........................................................................................................6-2
d. Range Switch Kit ....................................................................................................6-2
6-3 Matrix .......................................................................................................................... 6-3
7-0 RETURN OF MATERIAL.............................................................................................. 7-1
7-1 Return Of Material ........................................................................................................ 7-1
7-2 Customer Service .........................................................................................................7-1
7-3 Training........................................................................................................................ 7-1
ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model 7D
Figure 1-1. Model 7D Front Panel Controls........................................................................ 1-2
Figure 1-2. Model 7D – Location of Major Components...................................................... 1-3
Figure 1-3. Typical Gas Selector Panel ............................................................................. 1-4
Figure 2-1. Gas Selector Panel for Thermal Conductivity Cell with Sealed-In Reference
Figure 2-2. Gas Selector Panel for Thermal Conductivity Cell Using Flowing Reference
Figure 2-3. Connection of Analyzer Using Sealed-In Reference Gas to Associated Gas ....... 2-4
Figure 2-4. Connection of Analyzer Using Flowing Reference Gas to Associated Gas
Figure 2-5. Electrical Connections ..................................................................................... 2-6
Figure 2-6. Master Board.................................................................................................. 2-8
Figure 2-7. Alarm Adjustments ......................................................................................... 2-9
Figure 2-8. Typical Alarm Settings .................................................................................. 2-11
Figure 2-9. Case Heater Temperature Control Board ....................................................... 2-12
Figure 4-1. Thermal Conductivity Cell................................................................................ 4-3
Figure 6-1. Analyzer Assembly - Door and Pneumatic Components .................................... 6-4
Figure 6-2. Analyzer Assembly - Electronic Components.................................................... 6-5
Figure 6-3. Temperature Control Assembly ....................................................................... 6-6
Instruction Manual
748221-M
July 2002
LIST OF ILLUSTRATIONS
Gas ............................................................................................................... 2-2
Gas ............................................................................................................... 2-3
Selector Panel ................................................................................................ 2-5
LIST OF TABLES
Table 1-1. Available Gas Selector Panels......................................................................... 1-4
Table 2-1. Alarm Output Connections .............................................................................. 2-9
Table 4-1. Range Switch Connections .............................................................................. 4-2
LIST OF DRAWINGS
613561 Schematic Diagram, Bridge Power Supply - Regulated 5 to 15V
619710 Schematic Diagram, 15V Power Supply
624003 Schematic Diagram, Temperature Controller
652813 Schematic Diagram, Isolated Current Output
652863 Schematic Diagram, Linearizer Board
654616 Schematic Diagram, Master Board
654625 Installation Drawing, Model 7D
654642 Wiring Diagram, Model 7D
Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii
Instruction Manual
748221-M
July 2002
Model 7D
iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model 7D
PREFACE
The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of the Model 7D.
Some sections may describe equipment not used in your configuration. The user should
become thoroughly familiar with the operation of this module before operating it. Read
this instruction manual completely.
DEFINITIONS
The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout
this publication.
DANGER .
748221-M
July 2002
Highlights the presence of a hazard which will cause severe personal injury, death, or substantial
property damage if the warning is ignored.
WARNING .
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of perso nnel.
CAUTION.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.
NOTE
Highlights an essential operating procedure,
condition or statement.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1
Instruction Manual
748221-M
July 2002
Model 7D
INTENDED USE STATEMENT
The Model 7D is intended for use as an industrial process measurement device only. It is not intended for
use in medical, diagnostic, or life support applications, and no independent agency certifications or
approvals are to be implied as covering such application.
SAFETY SUMMARY
If this equipment is used in a manner not specified in these instructions, protective systems may be
impaired.
AUTHORIZED PERSONNEL
To avoid explosion, loss of life, personal injury and damage to this equipment and on-site
property, all personnel authorized to install, operate and service the this equipment should be
thoroughly familiar with and strictly follow the instructions in this manual. SAVE THESE
INSTRUCTIONS.
DANGER.
ELECTRICAL SHOCK HAZARD
Do not operate without doors and covers secure. Servicing requires access to live parts which can
cause death or serious injury. Refer servicing to qualified pe rsonnel.
For safety and proper performance this instrument must be connected to a properly grounded
three-wire source of power.
Before supplying electrical power to the analyzer, remove power to the bridge by disconnecting the
red lead from the bridge to TB1-1 or TB1-2 (depending on the bridge polarity). See drawing 654642.
To safeguard against filament damage, this lead should remain disconnected until proper gas flow
has been established.
WARNING.
ELECTRICAL SHOCK HAZARD
Do not operate the Model 7D Explosion-Proof Analyzer without the lens cover and door in place
with all bolts secured, unless location have been determined to be non-hazardous.
P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model 7D
WARNING.
POSSIBLE EXPLOSION HAZARD
Ensure that all gas connections are made as labeled and are leak free. Improper gas connections
could result in explosion or death.
WARNING .
POSSIBLE EXPLOSION HAZARD
This analyzer is of a type capable of analysis of sample gases which may be flammable. If used for
analysis of such gases, the instruments explosion-proof encl osure must be suitable for the gas.
If explosive gases are introduced into this analyzer, the sample containment system must be carefully leak-checked upon installation and before initial startup, during routine maintenance and any
time the integrity of the sample containment system is broken, to ensure the system is in leak-proof
condition. Leak-check instructions are provided in Section 2-4 on page 2-3.
748221-M
July 2002
Internal leaks resulting from failure to observe these precautions could result in an explosion
causing death, personal injury or property damage.
CAUTION .
PRESSURIZED GAS
This analyzer requires periodic calibration with known zero and standard gases. See General Precautions for Ha ndling and Storing High Pressure Gas Cylinders, page P-4
CAUTION
PARTS INTEGRITY
Tampering or unauthorized substitution of components may adversely affect safety of this product.
Use only factory documented components for repair.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3
Instruction Manual
748221-M
July 2002
Model 7D
GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH
PRESSURE GAS CYL INDERS
Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed
Gases" published in 1981
Compressed Gas Association
1235 Jefferson Davis Highway
Arlington, Virginia 22202
Used by Permission
1. Never drop cylinders or permit them to strike each other violently.
2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather
and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when
located in areas where extreme temper atures are prevalent.
3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or
placed in a cylinder stand, and is ready to be used.
4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a
suitable hand-truck.
5. Never tamper with safety devices in valves or cylinders.
6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is
attached to a pressurized system.
7. No part of cylinder should be subjected to a temperature higher than 125°F (52°C). A flame should never be
permitted to come in contact with any part of a compressed gas cylinder.
8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding,
precautions must be taken to prevent striking an arc against the cylinder.
P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model 7D
DOCUMENTATION
The following Model 7D instruction materials are available. Contact Customer Service Center or the local
representative to order.
748221 Instruction Manual (this document)
COMPLIANCES
The explosion-proof Model 7D is approved by Factory Mutual Research Corp. (FMRC) for installation in
Class I, Groups B, C, and D, Division 1 hazardous locations as defined in the National Electrical Code
(NEC), ANSI/NFPA-70.
FM
748221-M
July 2002
APPROVED
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5
Instruction Manual
748221-M
July 2002
Model 7D
P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model 7D
Instruction Manual
748221-M
July 2002
SECTION 1
DESCRIPTION AND SPECIFICATIONS
1-1 OVERVIEW
The Model 7D Thermal Conductivity Analyzer is
designed to continuously measure the
concentration of a single component of interest
in a flowing gas mixture. The measurement is
based on the different thermal conductivity's of
the individual components of the sample
stream. The method is especially well suited to
analysis of two-component sample streams.
However, analysis of multi-component streams
is possible if the various components of the
background gas occur in relatively constant
ratio, or have similar thermal conducti vity's.
Each Model 7D Analyzer is factory -assembled,
as ordered, for determination of a specified
component, with specified range of
concentration, contained in a background
component or background mixture of known
composition. Typical examples include: 0 to
100 % hydrogen in nitrogen; 20 to 50 % helium
in methane; and 0% to 3% carbon dioxide in air.
If so ordered, the instrument is provided with
two or three ranges; selectable via a front -panel
switch. Information specific to the individual
instrument is provided in the Data Sheet in the
rear of this manual inserted in the back of this
instruction manual.
A Model 7D Analyzer consists of an analyzer
module, Section 1-2 below, and, if ordered, an
accessory gas selector panel, Section 1-3 on
page 1-4.
1-2 ANALYZER MODULE
The analyzer module is supplied in an
explosion-proof enclosure suitable for
installation in hazardous locations classified as
Class I, Division 1, Groups B, C, and D per the
National Electrical Code (ANSI/NFPA 70) (See
DWG 654625).
a. Thermal Conductivity Cell
sample and reference gases. In all
applications, the sample passage
receives a continuous flow of sample
gas. Depending on the application, the
reference passage may receive a
continuous flow of reference gas, or
may have the reference gas sealed
within.
The sample passage contains a pair of
temperature-sensitive resistive
filaments. The reference passage
contains a similar pair. Electrically, the
filaments are connected as legs of a
Wheatstone bridge. An internal
voltage-regulated power supply is
connected via a 20-ohm dropping
resistor, to the bridge.
With the power supply output adjusted
to provide an appropriate voltage
across the bridge, an electric current
flows through the filaments, heating
them and thus increasing their electrical
resistance. The heat -dissipation rate
for each filament depends on the
thermal conductivity of the surrounding
gas.
Initially, with suitable downscale
calibration gas flowing through the
sample passage (and also through the
reference passage if of the flow-through
configuration), the bridge is balanced.
Thereafter, any change in the relative
proportions of the components passing
through the sample passage changes
the thermal conductivity of the gas
mixture, causing a temperature
differential between sample and
reference filaments. The resultant
change in filament resistance
unbalances the bridge, applying a
signal to the electronic circuitry (Section
1-2b on page 1-3).
The thermal conductivity cell is a metal
block with separate passages for the
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
Model 7D
748221-M
July 2002
ALARM 1 ALARM 2
50%
0% 100%
Rosemount Analytical
Model 7D
ZERO SPAN
RANGE
75%25%
1 3
50%
0% 100%
Model 7D
Thermal Conductivity
Analyzer
75%25%
2
ZERO SPAN
ALARM 1 ALARM 2
25%
50%
75%
RANGE
1 3
0% 100%
Rosemount Analytical
Figure 1-1. Model 7D Front Panel Controls
50%
2
25%
0% 100%
Thermal Conductivity
75%
Analyzer
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model 7D
Alarm Kit
±
15V Power Supply
Linearizer Board
Isolated Current Output Board
Bridge Power Supply
Temperature Control Assembly
Master Board
AC Power Input
Instruction Manual
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July 2002
b. Electronic Circuitry
The analyzer module contains solid-state
circuitry that conditions the
bridge-imbalance signal as required to
provide readout on the front -panel meter.
In addition, a field-selectable output for a
voltage-type recorder is provided as
standard. A field-selectable output of 4
to 20 mA for a current -actuated recorder
or other device is obtainable through use
of an optional plug-in circuit bo ard. A
calibration curve can be used to convert
meter or recorder readings into
concentration values. Typical calibration
curves are supplied for standard ranges.
Calibration curves for special ranges are
available as options.
To avoid use of a calibration curve in an
application where it would otherwise be
required, the analyzer may be equipped
with an optional linearizer board. If so,
the linearizer is factory set for a given
range only, and is not usable on another
range. Note that a linearizer is usable
only if nonlinearity at midscale does not
exceed approximately 20% of fullscale.
REF Hinge Side
Fuse
Cell Enclosure
Terminal Block TB6
Figure 1-2. Model 7D – Location of Major Components
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
Instruction Manual
CAL GAS
1 Reference Gas
Sample/Calibration
Downscale
Upscale
Sample Gas
1 Reference Gas
748221-M
July 2002
Model 7D
1-3 GAS SELECTOR PANEL
If so ordered, the analyzer module is provided
with an appropriate gas selector panel, Figure
1-3 below. The gas selector panel permits
selection, flow adjustment, and flow
measurement for the various gases: sample;
flowing reference gas, if used; and downscale
and upscale calibration gases. Proper choice
of a gas selector panel depends on:
Flow Meter
Calibration Gas
Needle Valve
DOWNSCALE
1. Configuration of the thermal conductivity
cell, i.e., flowing or sealed-in reference
gas.
2. Composition of the sample stream. For
non-corrosive streams, the gas selector
panel is assembled with brass
components. For corrosive streams,
stainless steel is used.
Gas Flow Meter
SAMPLE
Needle Valve
Calibration Gas
Needle Valve
UPSCALE
CAL GAS
REF
SAMPLE
REFERENCE
Needle Valve
1 Provided only if thermal conductivity cell uses flowing reference gas.
Figure 1-3. Typical Gas Selector Panel
DESCRIPTION PART NUM BER
Brass and Copper construction for use with sealed reference 113357
Stainless steel construction for use with sealed reference 113920
Brass and Copper construction for use with flowing reference 117195
Stainless steel construction for use with flowing reference 118210
Table 1-1. Available Gas Selector Panels
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model 7D
1-4 SPECIFICATIONS
Reproducibility ............................. ±0.5% of fullscale
Zero Drift1................................... ±1% of fullscale per 24 hours
Span Drift1................................... ±1% of fullscale per 24 hours
Noise.......................................... Less than ±0.5% of fullscale
Cell Response Time2................... 30 seconds for 95% response, with sample flow of 250 cc/min.
Sample Flow................................ Nominal, 50 to 350 cc/min; recommended, 250 cc/min.
Calibration Gas Flow.................... Nominal, 50 to 350 cc/min; recommended, 250 cc/min.
Reference Gas Flow (If Req’d) ...... 5 to 50 cc/min.
Supply Pressure.......................... 10 to 50 psig (69 to 345 kPa)
Meter .......................................... Indicating analog meter is standard.
Operating Ranges ........................ Various zero-based and zero-suppressed ranges, from 0% to
Ambient Temperature Range ........ 32°F to 100°F (0 °C to 38°C). Case Temperature controlled at
Output Voltage
Standard Non-Linearized....... Switch selectable: 0 to 10 mV, 0 to 100 mV, 0 to 1V or 0 to 5V DC
Optional Linearized ............... Switch selectable: 0 to 10 mV, 0 to 100 mV, 0 to 1V or 0 to 5V DC
Isolated Current Output (Option) ... 4 to 20 mA, maximum load 1500 ohms
Dual Alarms (Option).................... Relay contact rating: 1.0 A, 120V AC; 5.0 A, 120V DC, resistive
Cell Materials (Standard Cell) ....... 316 stainless steel block with tungsten or Hitempco filaments.
Power Requirements.................... 115/230 VAC ±10%, 50/60 Hz, 250 Watts
Enclosure.................................... Class I, Groups B, C and D, Division 1 hazardous locations
Instruction Manual
748221-M
July 2002
100%, are available. Single range is standard; switch-selectable
dual or triple range is optional.
117°F (47°C).
loads
Corrosion-resistant filaments available on order
(ANSI/NFPA 70)
1
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.
2
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
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