Rosemount Analytical
M
ODEL
N
-D
ON
I
NSTRUCTION MANUAL
ISPERSIVE INFRARED
A
NALYZER
880A
748250-L
OTICE
N
The information contained in this document is subject to change without notice.
This manual is based on the production version of the Model 880A Non-Dispersive Infrared Analyzer.
Hardware and/or software changes may have occurred since this printing.
Teflon® and Viton® are registered trademarks of E.I. duPont de Nemours and Co., Inc.
SNOOP® is a registered trademark of NUPRO Co.
Irtran™ is a trademark of Eastman Kodak Co.
Pyrex® is a registered trademark of Corning Glass Works.
Manual Part Number 748250-L
October 1999
Printed in U.S.A.
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
C
}
ONTENTS
P
REFACE
SAFETY SUMMARY...........................................................................................P-1
SPECIFICATIONS..............................................................................................P-3
OPTIONS SPECIFICATIONS.............................................................................P-4
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE ....P-5
RETURNING PARTS TO THE FACTORY .........................................................P-5
TRAINING ......................................................................................................P-5
DOCUMENTATION............................................................................................P-5
COMPLIANCES..................................................................................................P-6
S
ECTION
1.1 GENERAL DESCRIPTION.......................................................................1-1
1.2 AVAILABLE OPTIONS .............................................................................1-2
S
ECTION
2.1 UNPACKING.............................................................................................2-1
2.2 LOCATION ...............................................................................................2-1
2.3 VOLTAGE REQUIREMENTS...................................................................2-1
2.4 ELECTRICAL CONNECTIONS ................................................................2-2
2.5 SAMPLE INLET/OUTLET CONNECTIONS .............................................2-4
2.6 CALIBRATION GAS REQUIREMENTS....................................................2-4
2.7 SAMPLE HANDLING SYSTEM................................................................2-4
2.8 LEAK TEST PROCEDURE.......................................................................2-5
2.9 SAMPLE FLOW RATE .............................................................................2-6
1. I
2. U
2.4.1 Line Power Connections.............................................................2-2
2.4.2 Recorder Connections ................................................................2-3
NTRODUCTION
NPACKING AND INSTALLATION
2.10 OPTION BOARDS....................................................................................2-7
748250-L Rosemount Analytical October 1999
Model 880A Non-Dispersive Infrared Analyzer
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ONTENTS
S
ECTION
2.11 ORDERING OPTION KITS ......................................................................2-11
2.12 MOTOR SOURCE/REFERENCE CELL PURGE KITS............................2-11
S
ECTION
3.1 LEAK TEST..............................................................................................3-1
3.2 POWER VERIFICATION .........................................................................3-1
3.3 FRONT PANEL INDICATORS AND CONTROLS....................................3-2
2. (
2.10.1 Alarm Connections...................................................................2-8
2.10.2 Current Output Connections.....................................................2-8
2.10.3 Calibration Gas Control Connections.......................................2-8
2.10.4 Auto Zero/Span Connections ...................................................2-9
2.10.5 Remote Input/Output Connections...........................................2-9
3. I
3.3.1 Display ......................................................................................3-2
3.3.2 Function Keys.............................................................................3-2
3.3.3 User Programmable Keys...........................................................3-4
3.3.4 Run Mode Display...................................................................... 3-5
3.3.5 General Display Information.......................................................3-5
CONTINUED
NITIAL STARTUP AND CALIBRATION
)
3.4 ACCESSING MODE DISPLAYS..............................................................3-6
3.5 SECURITY CODE ...................................................................................3-6
3.6 RANGE PARAMETERS...........................................................................3-8
3.6.1 Range Selection.........................................................................3-8
3.6.2 Component of Interest................................................................3-9
3.6.3 Gain ......................................................................................3-9
3.6.4 Range, Fullscale.........................................................................3-9
3.6.5 Calibration Gas...........................................................................3-10
3.6.6 Zero Offset..................................................................................3-10
3.6.7 Time Constant............................................................................ 3-10
3.7 ANALYZER DIAGNOSTICS.....................................................................3-10
3.8 ZERO CALIBRATION ..............................................................................3-11
3.9 SPAN CALIBRATION...............................................................................3-11
3.10 LINEARIZATION...................................................................................... 3-12
3.10.1 All Range....................................................................................3-13
3.10.2 Non-Standard Ranges and Coefficients.....................................3-14
3.11 ALARM.....................................................................................................3-16
3.11.1 STATUS Display........................................................................3-17
3.12 CURRENT OUTPUT................................................................................3-18
3.13 ZERO/SPAN CALIBRATION WITH CALIBRATION GAS CONTROL .....3-18
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October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
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ONTENTS
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ECTION
3.14 AUTO ZERO/SPAN..................................................................................3-19
3.15 REMOTE RANGE INPUT/OUTPUT .........................................................3-22
S
ECTION
4.1 ROUTINE OPERATION............................................................................4-1
4.2 RECOMMENDED CALIBRATION FREQUENCY.....................................4-1
4.3 SHUTDOWN.............................................................................................4-1
4.4 DETECTION SYSTEM THEORY .............................................................4-1
S
ECTION
5.1 ERROR CODE SUMMARY ......................................................................5-1
5.2 VOLTAGE CHECKS.................................................................................5-3
5.3 OSCILLATOR TUNE ADJUSTMENT .......................................................5-3
5.4 PREAMP GAIN.........................................................................................5-3
3. (
4. R
5.
CONTINUED
OUTINE OPERATION AND THEORY
TROUBLESHOOTING
)
5.5 DIGITAL GAIN ADJUSTMENT.................................................................5-4
5.6 SOURCE BALANCE ADJUST..................................................................5-4
5.7 SOURCE ALIGNMENT.............................................................................5-6
5.8 SOURCE CURRENT ADJUSTMENT.......................................................5-6
5.9 CASE HEATER TEMPERATURE CONTROL..........................................5-6
5.10 ERL ERROR MESSAGE..........................................................................5-7
S
ECTION
6.1 CELL REMOVAL, CLEANING AND INSTALLATION...............................6-1
6.2 CELL DESICCANT...................................................................................6-4
6.3 SOURCE REPLACEMENT.......................................................................6-4
6.4 SOURCE BALANCE SHUTTER ADJUSTMENT......................................6-4
6.5 CHOPPER MOTOR ASSEMBLY..............................................................6-5
6. R
6.1.1 Long Cell Configurations .............................................................6-1
6.1.2 Short Cell Configurations............................................................6-2
6.5.1 Long Cell Configurations .............................................................6-5
6.5.2 Short Cell Configurations............................................................6-5
OUTINE SERVICING
6.6 MICRO BOARD REPLACEMENT ............................................................6-6
6.7 DETECTOR REPLACEMENT ..................................................................6-6
748250-L Rosemount Analytical October 1999
Model 880A Non-Dispersive Infrared Analyzer
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ONTENTS
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ECTION
6.8 ELECTRONIC CIRCUITRY ...................................................................... 6-9
6. (
6.7.1 Removal - Long Cell Configurations...........................................6-6
6.7.2 Removal - Short Cell Configurations ..........................................6-7
6.7.3 Detector Installation....................................................................6-7
6.8.1 Oscillator Circuit Board and Associated Elements of Amplitude
6.8.2 Functioning of Modulation System in TUNE Mode.....................6-9
6.8.3 Functioning of Modulation System in Operating Mode...............6-9
6.8.4 Radio Frequency Demodulator...................................................6-10
6.8.5 Signal Board...............................................................................6-10
6.8.6 Power Supply Board...................................................................6-10
6.8.7 Adapter Board ............................................................................6-11
6.8.8 Micro Board................................................................................ 6-11
6.8.9 Case Heater Temperature Control Board...................................6-11
6.8.10 Dual Alarm/Calibration Gas Control Board.................................6-11
6.8.11 Isolated Remote Input/Output Board..........................................6-12
6.8.12 Auto ZERO/SPAN Board............................................................6-12
6.8.13 Current Output Board.................................................................6-12
6.8.14 Auto Range Change...................................................................6-12
CONTINUED
Modulation Circuit.........................................................6-9
)
S
ECTION
7.1 CIRCUIT BOARD REPLACEMENT.........................................................7-1
7.2 SELECTED REPLACEMENT PARTS .....................................................7-1
ATA SHEET
D
ENERAL PRECAUTIONS FOR HANDLING
G
ARRANTY
W
IELD SERVICE AND REPAIR FACILITIES
F
7. R
7.2.1 Model 880A Common Parts ..........................................................7-2
7.2.2 Case Heater Temperature Control Assembly ................................ 7-2
7.2.3 Optical Bench................................................................................7-2
EPLACEMENT PARTS
TORING HIGH PRESSURE CYLINDERS
& S
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October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
F
IGURES
1-1 Model 880A Detection System .................................................................1-1
2-1 Power Supply Board.................................................................................2-2
2-2 Case Heater Temperature Control Board.................................................2-3
2-3 Cable Gland Connections.........................................................................2-3
2-4 Rear View of Model 880A.........................................................................2-7
2-5 Calibration Gas Control and Alarm Connections......................................2-8
2-6 Current Output Connections.....................................................................2-9
2-7 Auto Zero/Span Board Connections.........................................................2-10
2-8 Remote Input/Output Board Connections.................................................2-10
3-1 Model 880A Adjustments..........................................................................3-1
3-2 Model 880A Keypad.................................................................................3-3
3-3 Run Mode Display....................................................................................3-5
3-4 Logic Flow Chart .......................................................................................3-7
3-5 Security Mode...........................................................................................3-8
3-6 Range Mode.............................................................................................3-9
3-7 Diagnostic Mode.......................................................................................3-12
3-8 Linearizer Mode........................................................................................3-13
3-9 Typical Application Linearization Curve, Linearizer OFF..........................3-15
3-10 User Determined Linearization Curve (Normalized).................................3-15
3-11 Alarm Mode..............................................................................................3-16
3-12 Status Display...........................................................................................3-17
3-13 Current Output Mode................................................................................3-18
3-14 Auto Zero/Span ........................................................................................3-20
3-15 Remote Input/Output................................................................................3-22
5-1 Functional Block Diagrams.......................................................................5-2
5-2 Modulation System...................................................................................5-5
6-1 Cell Replacement .....................................................................................6-3
6-2 Motor/Source Assembly............................................................................6-5
6-3 Detector Replacement..............................................................................6-8
7-1 Model 880A Assembly..............................................................................7-3
7-2 Case Heater Temperture Control Assembly.............................................7-4
7-3 Optical Bench ...........................................................................................7-5
C
ONTENTS
748250-L Rosemount Analytical October 1999
Model 880A Non-Dispersive Infrared Analyzer
v
C
ONTENTS
T
ABLES
2-1 Purging Time at Atmospheric Sample Pressure ......................................2-6
3-1 Remote Range I/O Designation...............................................................3-23
3-2 Remote Range I/O Binary and Decimal Coding.......................................3-23
5-1 Error Code Summary...............................................................................5-1
6-1 Types of Desiccant...................................................................................6-4
6-2 Jumper Configurations for Option Boards................................................6-12
D
RAWINGS (LOCATED IN REAR OF MANUAL
623782 Schematic Diagram, Microprocessor Board
623995 Schematic Diagram, Oscillator Board
624003 Schematic Diagram, Case Heater Temperature Control Board
624085 Schematic Diagram, Signal Board
624092 Schematic Diagram, Isolated Voltage to Current Board
624127 Schematic Diagram, Adapter Board
624190 Installation Drawing, Model 880A
624204 Schematic Diagram, Dual Alarm/Fail Safe Alarm
624251 Schematic Diagram, Isolated Remote Control Board
624599 Schematic Diagram, Auto Zero/Span Board
655137 Schematic Diagram, Power Supply Board
655147 Pictorial Wiring Diagram, Model 880A
)
vi
October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
P
REFACE
S
AFETY 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
880A NDIR Analyzer should be thoroughly familiar with and strictly follow the
instructions in this manual.
Save these instructions.
DANGER
personal injury, death, or substantial property damage if the warning is ignored
WARNING
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION
personal injury or property damage if the warning is ignored.
NOTE
important but not hazard-related.
is used to indicate the presence of a hazard which
is used to indicate the presence of a hazard which
is used to indicate the presence of a hazard which
is used to indicate installation, operation, or maintenance information which is
will
will
can
or
cause
cause
can
cause
severe
severe
minor
WARNING: 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.
Alarm and zero/span switching relay contacts wired to separate power sources
must be disconnected before servicing.
This instrument is shipped from the factory set up to operate on 115 volt, 50/60
Hz electric power. For operation on 230 volt, 50/60 Hz power, see Section 2.3 for
modifications.
WARNING: PARTS INTEGRITY
Tampering or unauthorized substitution of components may adversely affect
safety of this product. Use only factory documented components for repair.
748250-L Rosemount Analytical October 1999
Model 880A Non-Dispersive Infrared Analyzer
P-1
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REFACE
WARNING: HIGH PRESSURE GAS CYLINDERS
This analyzer requires periodic calibration with known zero and standard gases.
Refer to Sections 2.6, 3.8, 3.9, 3.10 and 3.11. See also General Precautions for
Handling and Storing High Pressure Cylinders, following Section 7.
WARNING: POSSIBLE EXPLOSION HAZARD
This analyzer is of a type capable of analysis of sample gases which may be
flammable. If used for analysis of such gases the instrument must be protected
by a continuous dilution purge system in accordance with Standard ANSI/NFPA
496-1989, Chapter 8.
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 Paragraph 2.8.
Internal leaks resulting from failure to observe these precautions could result in
an explosion causing death, personal injury or property damage.
CAUTION: TOPPLING HAZARD
This instrument’s internal pullout chassis is equipped with a safety stop latch
located on the left side of the chassis.
When extracting the chassis, verify that the safety latch is in its proper (counterclockwise) orientation. If access to the rear of the chassis is required, the
safety stop may be overridden by lifting the latch; however, further extraction
must be done very carefully to insure the chassis does not fall out of its
enclosure.
P-2
If the instrument is located on top of a table or bench near the edge, and the
chassis is extracted, it must be supported to prevent toppling.
Failure to observe these precautions could result in personal injury and/or
damage to the product.
October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
S
PECIFICATIONS
P
OWER REQUIREMENTS
O
PERATING TEMPERATURE
D
IMENSIONS
:
P
REFACE
:
115/230 VAC ±10%, 50/60 ±3 Hz, 350 W
32°F to 113°F (0°C to 45°C)
:
8.7 in (22.0 cm) H
19 in. (48.3 cm) W
19 in. (48.3 cm) D, standard case
24 in. (61.0 cm) D, extended case
W
EIGHT
:
56 lbs (25 kg), standard case
68 lbs (31 kg), extended case
R
EPEATABILITY
N
Z
S
R
(ELECTRONIC
S
S
M
CELLS
TUBING
FITTINGS
S
:
OISE
ERO DRIFT
PAN DRIFT
ESPONSE TIME
ENSITIVITY
AMPLE CELL LENGTH
ATERIALS IN CONTACT WITH SAMPLE
AMPLE PRESSURE
1
:
1
:
:
W
INDOWS
O-R
:
:
)
:
INGS
:
:
:
:
:
:
1% of fullscale
1% of fullscale
±
±
Variable, 90% of fullscale in 0.5 sec to 20 sec, field
selectable. (Application dependent)
100 ppm fullscale carbon monoxide at atmospheric pressure
50 ppm fullscale carbon dioxide at atmospheric pressure
0.04 in. (1 mm) to 14.0 in. (381 mm)
Sapphire, quartz, Irtran
Gold plated Pyrex or stainless steel
FEP Teflon
316 stainless steel
Viton-A
Max 10 psig (69 kPa), standard
Pressurized application available upon request
1% of fullscale per 24 hours; ±2% of fullscale per week
1% of fullscale per 24 hours; ±2% of fullscale per week
A
NALOG OUTPUT
:
Standard: 0 to 5 VDC
Optional: 0 to 20 mA/4 to 20 Ma
L
INEARIZATION
E
NCLOSURE
1
Performance specifications based on ambient temperature shifts of less than 20°F (11°C) per hour.
2
When installed with user-supplied components, meets requirements for Class I, Division 2 locations per National
Electrical Code (ANSI/NFPA 70) for analyzers sampling non-flammable gases. Analyzers sampling flammable gases
must be protected by a continuous dilution purge system in accordance with Standard ANSI/NFPA 496-1989, Chapter 8.
Consult factory for recommendations.
748250-L Rosemount Analytical October 1999
:
:
Keypad entered coefficients for linearizing 1, 2 or all 3 ranges
General purpose for installation in weather-protected area.
Optional purge kit per Type Z, ANSI/NFPA 496-1989.
Model 880A Non-Dispersive Infrared Analyzer
2
P-3
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REFACE
O
PTIONS SPECIFICATIONS
A
LARM
Alarm Relay Outputs:
Two single point, field programmable high or low, deadband 5%
to 20% of fullscale.
Two form C contacts rated 3A-125/250 VAC or 5A-30 VDC
(resistive)
Z
ERO/SPAN
Relay Outputs:
Two front panel actuated contact closures
Two form C contacts rated 3A-125/250 VAC or 5A-30 VDC
(resistive)
A
UTO ZERO/SPAN
Relay Outputs:
Four form C contacts rated 3A-125/250 VAC or 5A-30 VDC
(resistive), field programmable frequency and duration of
closure.
Two form A contact closures for indication of insufficient zero
and span adjustment, rated (resistive load):
Max switching power: 10 Watts
R
EMOTE RANGE CHANGE
R
ELAY OUTPUTS
I
NPUTS
:
:
Max switching voltage: 30 VDC
Max switching current: 0.5 A
& ID
Three remotely changeable ranges with positive identification.
Binary code field selectable.
Eight form A contacts rated (resistive load):
Max switching power: 10 Watts
Max switching voltage: 30 VDC
Max switching current: 0.5 A
Eight optical couplers
Input Range: +5 VDC to +24 VDC
P-4
October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
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REFACE
C
USTOMER SERVICE
For order administration, replacement Parts, application assistance, on-site or factory
repair, service or maintenance contract information, contact:
R
ETURNING PARTS TO THE FACTORY
Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call:
Number.
Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sender, freight collect.
When returning any product or component that has been exposed to a toxic, corrosive
or other hazardous material or used in such a hazardous environment, the user must
attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification
that the material has been decontaminated, disinfected and/or detoxified.
Model Number, Serial Number, and Purchase Order Number or Sales Order
, T
ECHNICAL ASSIST ANCE AND FIELD SERVICE
Rosemount Analytical Inc.
Process Analytical Division
Customer Service Center
1-800-433-6076
Return to:
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
T
RAINING
A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the
the Technical Services Department at:
D
OCUMENTATION
The following Model 880A Non-Dispersive Infrared Analyzer instruction materials are
available. Contact Customer Service or the local representative to order.
748250 Instruction Manual (this document)
Current Operator and Service Training Schedule
Rosemount Analytical Inc.
Phone: 1-714-986-7600
FAX: 1-714-577-8006
contact
748250-L Rosemount Analytical October 1999
Model 880A Non-Dispersive Infrared Analyzer
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REFACE
C
OMPLIANCES
Model 880A Non-Dispersive Infrared Analyzers, Catalog Numbers 191811 (Standard)
and 191812 (Extended) when installed with optional Type Z Purge Kit P/N 624446 for
use in indoor Class I, Division 2, Groups B, C, and D hazardous locations and for use
in indoor non-hazardous locations when sampling flammable gases. When installed
without purge kit option, this equipment is intended for sampling only non-flammable
gases in non-hazardous locations.
This product may carry approvals from a certifying agency or may be in compliance with
EMC Directive. If so, the product will carry approval insignia, like those shown here, on the
product name rating plate.
FM
APPROVED
Rosemount Analytical Inc. has satisfied all obligations from the European Legislation to
harmonize the product requir ements in Europe.
This product complies with the standard level of NAMUR EMC. Recommendation
(May 1993).
This product satisfies all obligations of all relevant standards of the EMC framework in
Australia and New Zealand.
97-C209
NAMUR
N96
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October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
I
NTRODUCTION
1
1.1 GENERAL DESCRIPTION
The Model 880A Non-Dispersive Infrared Analyzer is designed to continuously
determine the concentration of a particular component of interest in a flowing gaseous
mixture. Within the analyzer, two equal energy infrared beams are directed through
two parallel optical cells, a flow-through sample cell and a reference cell. The Luft
detector continuously measures the difference in the amount of infrared energy
absorbed within each of the two cells. This difference is a measure of the
concentration of the component of interest in the sample.
Readout is on the 16-character, backlighted liquid crystal display in parts per million,
percent of composition or percent of fullscale. Additionally, a 0 to +5 VDC output for a
potentiometric (voltage) recorder is provided as standard.
A linearizer, based on a fourth-order polynomial, is incorporated in the electronic
circuitry. By turning the linearizer ON and entering the correct coefficients, an output
linear with concentration is obtained.
IGURE
F
1-1. M
ODEL
INFRARED
SOURCE
REFERENCE
CELL
DETECTOR
STATIONARY
BUTTON
SIGNAL
880A D
SIGNAL
CONDITIONING
CIRCUITRY
ETECTION SYSTEM
CHOPPER
SAMPLE IN
SAMPLE
CELL
SAMPLE OUT
DIAPHRAGM
DISTENDED
COMPONENT OF INTEREST
OTHER MOLECULES
748250-L Rosemount Analytical October 1999
Model 880A Non-Dispersive Infrared Analyzer
1-1
I
NTRODUCTION
1.2 AVAILABLE OPTIONS
Operation of the Model 880A can be enhanced with the choice of several options:
UAL ALARMS (STANDARD AND FAIL-SAFE
D
User-set dual alarms are available with configurable HI/LO designations and
deadband.
URRENT OUTPUT
C
For normal usage, the 0/4 to 20 mA current output can be set to represent 0 to 100%
of fullscale, or a suppressed range of 25% or more of fullscale may be selected.
UTO ZERO/SPAN
A
An Automatic Zero/Span is available for unattended calibration of all three ranges.
ALIBRATION GAS CONTROL
C
A Calibration Gas Control allows two solenoids to be remotely actuated from the front
panel, enabling one-man calibration without leaving the analyzer.
)
EMOTE RANGE SELECTION AND
R
A remote range change and ID is available.
ASE HEATER
C
A proportional temperature controller with fan assembly maintains proper operating
temperature inside the case.
URGE KITS
P
An air purge kit, when installed with user-supplied components, meets Type Z
requirements of standard ANSI/NFPA 496-1989 for installation in Class I, Division 2
locations as defined in the National Electrical Code (ANSI/NFPA 70) when sampling
non-flammable gases. If analyzer is used to sample a flammable gases it must be
protected by a continuous dilution purge system per standard ANSI/NFPA 496-1989,
Chapter 8. Consult factory for further information.
A motor source or motor source/reference cell purge kit accompanies some
configurations of the Model 880A. The purpose for these kits is reduction of ambient
CO2 interference and, thus, improved performance and accuracy. These purges do
not provide explosion hazard protection.
ID
1-2
October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
U
NPACKING AND INSTALLATION
2
2.1 UNPACKING
Carefully examine the shipping carton and contents for signs of damage. Immediately
notify the shipping carrier if the carton or its contents are damaged. Retain the carton
and packing material until the instrument is operational
2.2 LOCATION
Locate the analyzer in a weather-protected, non-hazardous location free from
vibration. For best results mount the analyzer near the sample stream to minimize
sample-transport time. Refer to Installation Drawing 624190.
If equipped with P/N 624446 air purge kit and installed with user-provided
components per Instructions 015-748157, the analyzer may be located in a Class I,
Division 2 area as defined by the National Electrical Code (ANSI/NFPA 70). This kit is
designed to provide Type Z protection in accordance with Standard ANSI/NFPA
496-1989, Chapter 2, when sampling nonflammable gases. For flammable samples,
the instrument must be equipped with a continuous dilution purge system in
accordance with ANSI/NFPA 496-1989, Chapter 8.
2.3 VOLTAGE REQUIREMENTS
WARNING: ELECTRICAL SHOCK HAZARD
For safety and proper performance, this instrument must be connected to a
properly grounded three-wire source of electrical power.
This instrument was shipped from the factory configured to operate on 115 VAC,
50/60 Hz electric power. For operation on 230 VAC, 50/60 Hz, voltage select switches
S1, S2, located on Power Supply Board (Figure 2-1) and, if installed, S3, located on
the Case Heater Temperature Control Board Figure 2-2 (see Figure 7-2, Case Heater
Temperature Control Assembly) must be in the 230 VAC position. Power consumption
is 350 watts.
748250-L Rosemount Analytical October 1999
Model 880A Non-Dispersive Infrared Analyzer
2-1
U
G
NPACKING AND INSTALLATION
2.4 ELECTRICAL CONNECTIONS
The power, recorder and current output cable glands are shipped already installed to
allow attachment of cables to connectors or terminal strips. Cable glands for specific
cables are as follows:
CABLE GLAND PART NO.
P
OWER
R
ECORDER
O
PTION BOARD
Remove the rear cover to access the terminals. Route each cable through the cable
gland and connect to appropriate connector or terminal strip, tighten the gland.
Set switch windows for voltage required
115 115
TEMP
CONTROL
CASE
J5
1
J16
R11
1
4 3 2 1
899330
899329
899329
S2 S1
S2 S1
230V
115V
DETECTOR
HEATER
J2
J4
1
K1
TP1
C12
I
I
R12 R13
C10
C11
C9
TP2
C6
+
C8
+
+
+
C5
C7
+
+
R1
R2
S3
SS LUFT
8
1
2
7
6
3
45
+
C4
+
CR4
CR3
CR2
+
C2
+
+
C3
+
+
C1
FAN
1
VR2
VR4
I
G
VR3
I
G
O
O
VR1
G
G
O
O
R3
R10
R8
R4
R5
R6
R7
AR1
- CR1 +
R9
R34
R35
R36
R39
R18
C14
C13
C18
U1
+
+
C
E
Q3
AR4
R37
R20
R16
R15
C16
R31
R30
R27
R28
R32
CR6
CR7
R33
B
CR5
R19
Q4
U2
AR5
C20
R14
C19
R17
CR8
R25
R29
R26
B
E
Q2
C
C15
AK
Q1
R21
R22
C21
R
38
+
J
10
J14
1
1
J11
J8
1
J15
R24
1
R23
1
J13
J7
IGURE
F
2.4.1 L
2-1. P
OWER SUPPLY BOARD
INE POWER CONNECTIONS
655135 POWER SUPPLY BD
1
Heater LED (CR5)
Refer to Figures 2-3, 2-4 and drawing 624190. If this instrument is located on a bench
or table top or is installed in a protected rack, panel or cabinet, power may be
connected via a 3-wire flexible power cord, minimum 18 AWG (max. O.D. 0.480",
min. O.D. 0.270") through hole labeled POWER, utilizing connector gland (P/N
899330) provided.
2-2
October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
U
NPACKING AND INSTALLATION
Set switch w in do w fo r volta g e required
S3
IGURE
F
2-2. C
POWER
SUPPLY
R6
C3
R9 R5
1
CR3
E
B
Q3
TEST
C
R10 R11 R7 R8
C2
CR1
C
B
Q2
SENSOR J18
400A 880 951E
R17R16 R12CR2
R4
R3
C1
E
+
TEMP CONTROL BD
1
AR1
R13
R2R1
Q1
K
G
A
ASE HEATER TEMPERATURE CONTROL BOARD
J19
J11
R15
POWER
LINE
J5
C4
3 2 1
R14
1
U1
1 2 1 2 3
T.I.F. HEATER
U2
2
3
1
J17
S3
230
115
115
Accessory kits are available which include one of the following: 1) a 10-foot North
American power cord set and four enclosure support feet (P/N 654008) for bench top
use, 2) the power cord only (P/N 634061), or 3) the four feet only (P/N 634958). If the
instrument is permanently mounted in an open panel or rack, use electrical metal
tubing or conduit.
Route the power cable through the cable gland and connect the leads to TB1. After
connecting the leads, tighten the cable gland adequately to prevent rotation or
slippage of the power cable. Since the rear terminals do not slide out with the chassis,
no excess power cable slack is necessary.
INTERIOR EXTERIOR
Nut Gland Nut
Cable
Case Wall
IGURE
F
2-3. C
ABLE GLAND CONNECTIONS
748250-L Rosemount Analytical October 1999
Model 880A Non-Dispersive Infrared Analyzer
2-3
U
NPACKING AND INSTALLATION
2.4.2 R
ECORDER CONNECTIONS
Refer to Figures 2-3, 2-4 and drawing 624190. Recorder connections are made to the
rear panel. Route the recorder cable through the cable gland in hole labeled
RECORDER OUTPUT and connect to TB2.
Recorder and interconnection cables should meet the following requirements:
OLTAGE OUTPUT
V
Maximum distance from recorder to analyzer: 1000 ft. (305 m)
•
Recorder input impedance: >5000 ohms
•
Customer-supplied cable: 2-conductor, 20 AWG (min.), shielded
•
URRENT OUTPUT
C
Maximum load impedance: 700 ohm
•
: 0
: 0
TO
+5 VDC
TO
20 MA
OR 4 TO
20 MA (
KEYBOARD PROGRAMMABLE
2.5 SAMPLE INLET/OUTLET CONNECTIONS
Most applications of the Model 880A are intended for atmospheric pressure operation
with venting to the atmosphere. High pressure and sub-atmospheric pressure
applications require careful regulation of the sample pressure. Sample inlet and outlet
connections are located on the rear panel. All connections are 1/4-inch ferrule-type
compression fittings.
)
2.6 CALIBRATION GAS REQUIREMENTS
Analyzer calibration consists of setting a zero point and one upscale point per range.
All applications require a zero standard gas to set the zero point on the display or
recorder chart.
If the factory Calibration and Data Sheet (included with the drawings at the end of the
manual) specifies a background gas, use this as the zero gas. If a background gas is
not specified, use dry nitrogen for the zero gas.
Ideally, span gas should be between 75% and 100% of the fullscale span.
2.7 SAMPLE HANDLING SYSTEM
Many different sample handling systems are available, either assembled completely or
as loose components. The type used depends on the requirements of the particular
application and the preferences of the individual user. Typically, the sample handling
system incorporates such components as pumps and valves to permit selection of
sample, zero standard and upscale standard gas; needle valve in sample-inlet line for
flow adjustment; flowmeter for flow measurement and/or indication of flow stoppage;
and filter(s) to remove particulate matter.
2-4
October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
U
NPACKING AND INSTALLATION
2.8 LEAK TEST PROCEDURE
To check for leaks in the sample system, do the following:
1. Supply air or inert gas such as nitrogen to the sample inlet of the analyzer at 10
psig (69 kPa).
2. Seal off sample outlet with a cap, and turn off supply of inert gas. After 1 hour,
pressure reading should not drop. If it does, the system is leaking. Continue with
steps 3 thorough 4 to locate source of leak.
3. Use a suitable test liquid such as SNOOP (P/N 837801) to detect leaks. Cover all
fittings, seals or possible leak sources.
4. Check for bubbling or foaming which indicates leakage and repair as required. Any
leakage must be corrected before introduction of sample and/or application of
electrical power.
5. For smaller leaks, use a Halogen or helium leak detection device.
WARNING: POSSIBLE EXPLOSION HAZARD
This analyzer is of a type capable of analyzing sample gases which may be
flammable. If used for analysis of such gases the instrument must be protected
by a continuous dilution purge system in accordance with Standard ANSI/NFPA
496-1989, Chapter 8.
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 this section.
Internal leaks resulting from failure to observe these precautions could result in
an explosion causing death, personal injury or property damage.
Note
Apply test liquid to cell or detectors and IR source windows only as a last
resort. Should this occur, follow instructions in Section 6.1 to clean these
components.
748250-L Rosemount Analytical October 1999
Model 880A Non-Dispersive Infrared Analyzer
2-5
U
NPACKING AND INSTALLATION
2.9 SAMPLE FLOW RATE
Recommended sample flow rate is 1 to 2 SCFH (500 to 1000 cc/min). A subnormal
flow rate will not affect readings but may result in an undesirable time lag. However,
an excessive flow rate can result in cell pressurization and reading error.
Assume that two cell volumes are required to flush any cell. Approximate flushing time
for the Model 880A's 12-inch cell at atmospheric sampling pressure (i.e., the outlet of
the cell venting to atmosphere) is approximately 12 seconds. Flushing time decreases
with cell volume (see Table 2-1). Flushing time is inversely proportional to flow rate.
The primary effect of flow rate, other than flushing time, is cell pressure. Due to
restrictions in exit flow configuration, an increasing flow rate increases sample
pressure in the cell.
In all cases, the effect of pressure on readout is eliminated if the same flow rate is
used for the measured sample as well as for the zero gas and span gas.
Note that at higher flow rates the nonlinearity of the calibration curve increases,
because of increase in sample cell pressure. Therefore, if higher flow rates are
required, the calibration curve should be redrawn at the higher rate.
At flows up to 2 CFH (1 L/min), gaseous sample temperatures are equilibrated to
instrument temperature regardless of stream temperature. At extremely high flow
rates, this may not be true, but no such effect has been noted up to 18 CFH (9 L/min).
TIME FOR 2
VOLUMES
CELL LENGTH
MM INCH
CELL VOLUME IN CC
WITHOUT INLET
TUBE
TOTAL VOLUME IN CC
CELL WITH INLET
TUBE
AT 2 SCFH (1 L/MIN)
AT 750 MM HG
3 0.118 0.85 12 2 sec.
4 0.157 1.14 12 2 sec.
8 0.315 2.28 13 2 sec.
16 0.630 3.56 16 2 sec.
32 1.25 9.12 20 2 sec.
64 2.52 18.24 25 3 sec.
128 4.03 35.48 44 3 sec.
232 9.13 65.12 73 6 sec.
343 13.50 97.76 105 13 sec.
381 15.00 108.60 116 14 sec.
ABLE
T
2-1. P
URGING TIME AT ATMOSPHERIC SAMPLE PRESSURE
2-6
October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
U
NPACKING AND INSTALLATION
PURGE GAS
OUTLET
OPTION BOARDS INSTALLED WITH COMPONENT SIDE TO THE LEFT.
REFERENCE
OUT IN
Auto Zero/Span Control Board
Isolated V/I Board
Dual Alarm Board
Isolated Remote Control Board
Calibration Gas Control Board
SAMPLE
OUT IN
OPTIONS CONNECTIONS
RECORDER
OUTPUT POWER
F1 4A
RESETTABLE
CIRCUIT
BREAKER
+ - GND
TB2
PURGE GAS
TB1
GND
NEUT/L2
HOT/L1
Recorder Output
Hook-Up
IN
Power
Hook-UP
IGURE
F
2-4. R
EAR VIEW OF MODEL
880A
2.10 OPTION BOARDS
The following option boards may be ordered factory installed or as kits from the factory
at a later date: Alarm, Current Output, Calibration Gas Control, Auto Zero/Span and
Remote Range I/O. The boards are supplied with outlet connector mating plugs
installed on each board for field wiring. Attach the cable (customer supplied) to the
outlet connector plug per the appropriate schematic diagram for each option board.
If an option board has been ordered installed at the factory, this board will be inserted
into one of
five slots inside the rear of the analyzer (See Figure 2-4). Each option will require a
cable (user-provided) which connects to a female plug. The female plug, in original
packaging, is attached to the appropriate terminal block on the option board. If the
instrument came equipped with one option, the interconnect cable will be in place for
all options. The Alarm, Auto Zero/Span, Calibration Gas Control and Remote Range
Change Boards have jumper-selectable addresses (Figures 2-5, 2-7 and 2-8, Section
6.8 and Table 6-2).
748250-L Rosemount Analytical October 1999
Model 880A Non-Dispersive Infrared Analyzer
2-7
U
NPACKING AND INSTALLATION
Outlet
Cable
J2
R5
R4
R3
A
C
B B
Jumper Selectable
Address
E4 E2 E1
R1
R2
R8
R6
C
E
FT2FT1
Q1
B
CR1
1
A
E
Q2
C
R7
B
E8
E6
1
CR2
C
1
E10
E9
E7
1
E5
C1
PR1
C1
U1
U2
U3
C3
J1
1
+
R9
Interconnect
Cable
K1
624419 CTR L
CAL
K2
624207 ALA RM
DUAL
1
FAIL
654398 SAF E A LAR M
U4
Note: The Dual Alarm, Fail Safe Alarm and Calibration Gas Control use the same board. However, the jumpers
locations are different.
Cal Gas Control: E1, E4, E5 - E7 and E9 - E10
Dual Alarm: E1, E2, E5 - E7 and E9 - E10
Fail Safe Alarm: E1, E2, E6 - E7 and E8 - E10
IGURE
F
2-5. C
2.10.1 A
LARM CONNECTIONS
ALIBRATION GAS CONTROL AND ALARM CONNECTIONS
Refer to Figures 2-3, 2-5 and drawing 655147. Connect cable (customer supplied) to
the 6-pin connector J2. The Dual Alarm consists of two form C contacts rated
3A-125/250 VAC or 5A-30 VDC (resistive).
Run the cable through the cable gland and tighten once the connector has been
secured.
2.10.2 C
URRENT OUTPUT CONNECTIONS
Refer to Figures 2-3, 2-6 and Drawing 655147. Connect cable (customer supplied) to
the 2-pin connector J2. The voltage-to-current board has a fixed address at the top of
the board.
Run the cable through the cable gland and tighten once the connector has been
secured.
2.10.3 C
Refer to Figures 2-3, 2-5 and Drawing 655147. Connect cable (customer supplied) to
the 6-pin connector J2. The Calibration Gas Control consists of two form C contacts
rated 3A-125/250 VAC or 5A-30 VDC (resistive). Run the cable through the cable
gland and tighten the latter once the connector has been secured.
2-8
ALIBRATION GAS CONTROL CONNECTIONS
October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
U
NPACKING AND INSTALLATION
2.10.4 A
UTO ZERO/SPAN CONNECTIONS
Refer to Figures 2-3, 2-7 and Drawing 655147. Connect cable (customer supplied) to
the 9-pin connectors J2 and J3. The Auto Zero/Span consists of four form C contacts
rated 3A-125/250 VAC or 5A-30 VDC (resistive) and two form A contacts rated at 10
watts maximum switching power, 200 VDC maximum switching voltage and 0.5 A
maximum switching current.
Run the cable through the cable gland and tighten once the connector has been
secured.
If installed, this board can also be activated from the keyboard (Zero/Span) for the
selected range.
2.10.5 R
EMOTE INPUT/OUTPUT CONNECTIONS
Refer to Figures 2-3, 2-8 and Drawing 655147. Connect cable (customer supplied) to
the 9-pin connectors J2 and J3.
The signal output is at J2 which consists of eight form A contacts rated (resistive load)
10 watts, maximum switching power, 200 VDC maximum switching voltage and 0.5 A
maximum switching current.
The signal input is at J3 which consists of eight optocouplers, operated from a
user-supplied 24 VDC power source.
Run the cable through the cable gland and tighten once the connector has been
secured.
Outlet
Cable
C1 C2
SPAN
R1
OFFSET
R2
+ CR1
J2
1
1
VR1
VR2
AR1
624095 ISOLATED V TO I BD
U3
U1
1
U2
G
R6
R5
R4
G
R3
1
1
C4 C 5 C 6
U4
C8
+
C7
++
O
I
O
I
I
C3
J1
1
Interconnect
Cable
IGURE
F
748250-L Rosemount Analytical October 1999
2-6. C
URRENT OUTPUT CONNECTIONS
Model 880A Non-Dispersive Infrared Analyzer
2-9
U
NPACKING AND INSTALLATION
Jumper Selectable
Address
IGURE
F
Outlet
Cable
2-7. A
J2
J3
FT1 K1
FT2 K2
FT3
C
Q1
CR1
C
Q2
CR2
C
Q1
CR3K3R6
B
E
R4
K5
B
E
R5
K6
B
E
C
Q5
CR5
C
Q1
B
R8
B
K4FT4
E
RP1
E
UTO ZERO/SPAN BOARD CONNECTIONS
Jumper Selectable
Address
R10
1
U3
U1
C3
R1R1
R2
R3
1
1
B
E
R7
C2
C1
+
E4 E2 E1
J1
1
C
Q4
CR4
Interconnect
Cable
1
U2
1 U4
IGURE
F
Outlet
Cable
2-8. R
CR1 R13
K5
K6
K7
K8
R7
R8
R9
R10
E4
E2
C5
E1
U1
1
RP2
1
1
C2
1
1
11
U2
J2
J3
R11
K1
K2
K3
K4
R3
R4
R5
R6
R2
R1
E9E8
E5 E6 E7
624254 654416 ISOLA TE D R EM O T E C O NT R OL B D
EMOTE INPUT/OUTPUT BOARD CONNECTIONS
C4
U3
U7
C3
R12
U4
RP1
C1
Interconnect
J1
+
1
U5U6
Cable
2-10
October 1999 Rosemount Analytical 748250-LModel 880A Non-Dispersive Infrared Analyzer
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