Rosemount Analytical
M
ODEL
N
I
NFRARED ANALYZER
I
NSTRUCTION MANUAL
ON
-D
880
ISPERSIVE
748176-N
OTICE
N
This Model 880 instruction manual is for use with instruments with a software version of 2.0 or greater.
The information contained in this document is subject to change without notice.
Irtran is a Registered Trademark of Eastman Kodak Co.
Pyrex is a Registered Trademark of Corning Glass Works
Teflon and Viton are Registered Trademarks of E.I. duPont de Nemours and Co., Inc.
SNOOP is a Registered Trademark of NUPRO Co.
Model SGD Series-710 Standard Gas Divider is a Registered Trademark of STEC Inc.
Manual Part Number 748176-N
July 1998
Printed in U.S.A.
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
C
ONTENTS
PREFACE
SAFETY SUMMARY ..........................................................................................P-1
SPECIFICATIONS..............................................................................................P-3
SPECIFICATIONS - OPTIONS ..........................................................................P-5
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE....P-6
RETURNING PARTS TO THE FACTORY.........................................................P-6
TRAINING ......................................................................................................P-6
DOCUMENTATION............................................................................................P-6
QUICK STARTUP AND TROUBLESHOOTING GUIDE.....................................P-7
S
ECTION
1.1 GENERAL DESCRIPTION........................................................................1-1
1.2 AVAILABLE OPTIONS..............................................................................1-1
1. I
NTRODUCTION
SECTION 2. UNPACKING AND INSTALLATION
2.1 UNPACKING............................................................................................2-1
2.2 LOCATION...............................................................................................2-1
2.3 VOLTAGE REQUIREMENTS...................................................................2-1
2.4 ELECTRICAL CONNECTIONS................................................................2-3
2.4.1 Line Power Connections..............................................................2-4
2.4.2 Recorder Connections.................................................................2-4
2.5 SAMPLE AND REFERENCE INLET/OUTLET CONNECTIONS..............2-4
748176-N
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S
ECTION
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
2.10 DIFFERENTIAL ANALYSIS WITH FLOW-THROUGH
2.11 OPTION BOARDS................................................................................... 2-7
2.12 ORDERING OPTION KITS.................................................................... 2-11
2. (
2.11.1 Alarm Connections................................................................... 2-7
2.11.2 Current Output Option Connections......................................... 2-8
2.11.3 Calibration Gas Control Connections....................................... 2-9
2.11.4 Auto Zero/Span Connections................................................... 2-9
2.11.5 Remote Input/Output Connections........................................... 2-10
CONTINUED
REFERENCE CELL...................................................................... 2-7
)
SECTION 3. INITIAL STARTUP AND CALIBRATION
3.1 LEAK TEST.............................................................................................. 3-1
3.2 POWER VERIFICATION ......................................................................... 3-1
3.3 SOFTWARE VERSION ........................................................................... 3-1
3.4 FRONT PANEL INDICATORS AND CONTROLS ................................... 3-1
3.4.1 Display 3-1
3.4.2 Function Keys............................................................................. 3-3
3.4.3 User-Programmable Keys.......................................................... 3-4
3.4.4 Run Mode Display...................................................................... 3-5
3.4.5 General Display Information....................................................... 3-5
3.5 ACCESSING MODE DISPLAYS.............................................................. 3-6
3.6 SECURITY CODE.................................................................................... 3-6
3.7 RANGE PARAMETERS........................................................................... 3-10
3.8 ANALYZER DIAGNOSTICS .................................................................... 3-13
3.9 ZERO CALIBRATION.............................................................................. 3-13
3.9.1 Hardware and Software Zero..................................................... 3-13
3.9.2 Calibrating the Analyzer with Zero Gas...................................... 3-14
II
Rosemount Analytical
July 1998
748176-N
SECTION 3. (CONTINUED)
3.10 ZERO CALIBRATION FOR THE ANALYZER WITH THE CAL GAS
CONTROL OPTION......................................................................3-17
3.10.1 Calibrating the Analyzer with the Calibration Gas Control
Option with Zero Gas....................................................3-17
3.11 SPAN CALIBRATION..............................................................................3-17
3.11.1 Hardware and Software Settings for Span Gas........................3-17
3.11.2 Calibrating the Analyzer with Span Gas....................................3-18
3.12 SPAN CALIBRATION FOR THE ANALYZER WITH THE CAL GAS
CONTROL OPTION......................................................................3-19
3.13 LINEARIZATION .....................................................................................3-20
3.14 ALARM OPTION .....................................................................................3-24
3.14.1 STATUS Display.......................................................................3-26
ONTENTS
C
3.15 CURRENT OUTPUT OPTION.................................................................3-26
3.16 AUTO ZERO/SPAN OPTION..................................................................3-27
3.17 REMOTE RANGE INPUT/OUTPUT OPTION .........................................3-30
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
4. R
OUTINE OPERATION AND THEORY
SECTION 5. TROUBLESHOOTING
5.1 ERROR CODE SUMMARY......................................................................5-1
5.2 OSCILLATOR TUNE ADJUSTMENT.......................................................5-2
5.3 PREAMP GAIN.........................................................................................5-2
5.4 SOURCE BALANCE SHUTTER ADJUSTMENT......................................5-3
5.5 SOURCE CURRENT ADJUSTMENT.......................................................5-3
5.6 VOLTAGE CHECKS.................................................................................5-3
5.7 DIGITAL GAIN ADJUSTMENT.................................................................5-3
748176-N
July 1998
Rosemount Analytical
III
M
ODEL
880 NON-D
ISPERSIVE INFRARED ANALYZER
SECTION 5. (CONTINUED)
5.8 CASE HEATER TEMPERATURE CONTROL.........................................5-4
5.9 DETECTOR HEATER.............................................................................. 5-4
SECTION 6. ROUTINE SERVICING
6.1 CELL REMOVAL, CLEANING AND INSTALLATION.............................. 6-1
6.2 CELL DESICCANT .................................................................................. 6-2
6.3 SOURCE REPLACEMENT...................................................................... 6-2
6.4 SOURCE BALANCE SHUTTER ADJUSTMENT..................................... 6-3
6.5 CHOPPER MOTOR ASSEMBLY (PN 658313)....................................... 6-3
6.6 MICROBOARD REPLACEMENT ............................................................ 6-3
6.7 DETECTOR REMOVAL........................................................................... 6-4
6.8 ELECTRONIC CIRCUITRY ..................................................................... 6-4
6.8.1 Oscillator Circuit Board and Associated Elements of Amplitude-
Modulation Circuit......................................................... 6-4
6.8.2 Functioning of Modulation System in TUNE Mode...................... 6-5
6.8.3 Functioning of Modulation System in Operating Mode................ 6-5
6.8.4 Radio-Frequency Demodulator................................................... 6-6
6.8.5 Signal Board (DWG 624085) ...................................................... 6-6
6.8.6 Power Supply Board (DWG 624073) .......................................... 6-6
6.8.7 Adapter Board (DWG 624127).................................................... 6-6
6.8.8 Microboard.................................................................................. 6-6
6.8.9 Optional Case Heater Temperature Control Board
(DWG 624003) ............................................................. 6-7
6.8.10 Dual Alarm/Calibration Gas Control Option Board
(DWG 624204) ............................................................. 6-7
6.8.11 Isolated Remote Range I/O Option Board (DWG 624251) ......... 6-7
6.8.12 Auto Zero/Span Option Board (DWG 624599)............................ 6-8
6.8.13 Current Output Option Board (DWG 624092)............................. 6-8
SECTION 7. REPLACEMENT PARTS
7.1 CIRCUIT BOARD REPLACEMENT POLICY............................................ 7-1
7.2 SELECTED REPLACEMENT PARTS...................................................... 7-1
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GENERAL PRECAUTIONS FOR HANDLING & STORING HIGH PRESSURE CYLINDERS
WARRANTY
FIELD SERVICE AND REPAIR FACILITIES
F
IGURES
2-1 Power Supply Board ..............................................................................2-2
2-2 Case Heater Temperature Control Board...............................................2-2
2-3 Rear View of Model 880.........................................................................2-3
2-4 Cable Gland ...........................................................................................2-3
2-5 Calibration Gas Control and Alarm Connections....................................2-8
2-6 Current Output Connections...................................................................2-8
2-7 Auto Zero/Span Connections................................................................2-9
2-8 Remote Input/Output Connections.........................................................2-10
3-1 Model 880 Adjustments..........................................................................3-2
3-2 Model 880 Keypad .................................................................................3-2
3-3 Run Mode Display..................................................................................3-5
3-4 Logic Flow Chart..................................................................................... 3-7
3-5 Accessing the Security Lockout Feature................................................3-9
3-6 Activating/Deactivating the Security Lockout Feature ............................3-9
3-7 Changing the Password.........................................................................3-10
3-8 Setup/Checkout of Range Parameters...................................................3-12
3-9 Analyzer Diagnostics..............................................................................3-13
3-10 Viewing the Zero Display........................................................................3-15
3-11 Changing the Zero Setting......................................................................3-15
3-12 Changing the Zero Setting for Analyzers with Calibration Gas Control..3-16
3-13 Viewing the Span Setting.......................................................................3-16
3-14 Changing the Span Setting.....................................................................3-19
3-15 Changing the Span Setting for Analyzers with Calibration Gas Control.3-20
3-16 Typical Application Linearization Curve..................................................3-22
3-17 User-Determined Linearization Curve....................................................3-22
3-18 Data Points for User-Determined Linearization Coefficients..................3-23
3-19 Setup/Checkout of Linearization Function..............................................3-24
3-20 Setup/Checkout of Alarm Option............................................................3-25
3-21 Status Display ........................................................................................3-26
3-22 Setup/Checkout of Current Output Option .............................................3-27
3-23 Setup/Checkout of Auto Zero/Span Option............................................3-29
3-24 Setup/Checkout of Remote Input/Output Option....................................3-31
4-1 Functional Diagram of Detection System...............................................4-2
5-1 Troubleshooting Chart............................................................................5-5
5-2 Signal Waveforms..................................................................................5-6
5-3 Modulation System.................................................................................5-7
748176-N
July 1998
Rosemount Analytical
V
M
ODEL
880 NON-D
ISPERSIVE INFRARED ANALYZER
FIGURES (CONTINUED)
7-1 Case Heater Temperature Control Assembly........................................ 7-2
7-2 Motor/Source Assembly......................................................................... 7-3
7-3 Model 880 Major Components............................................................... 7-4
7-4 Optical Bench Assembly........................................................................ 7-5
7-5 Detector Assembly Removal/Installation ............................................... 7-6
T
ABLES
2-1 PURGING TIME AT ATMOSPHERIC SAMPLE PRESSURE ............... 2-6
3-1 REMOTE RANGE I/O BIT DESIGNATION............................................ 3-32
3-2 REMOTE RANGE I/O BINARY AND DECIMAL BIT CODING .............. 3-32
5-1 ERROR CODE SUMMARY................................................................... 5-1
D
RAWINGS (LOCATED IN REAR OF MANUAL
623782 Schematic Diagram, Microprocessor Board
623995 Schematic Diagram, Oscillator Board
624003 Schematic Diagram, Temperature Controller
624073 Schematic Diagram, Power Supply
624085 Schematic Diagram, Signal Board
624092 Schematic Diagram, Isolated Voltage to Current
624127 Schematic Diagram, Adapter Board
624190 Installation Drawing, Model 880
624191 Pictorial Wiring Diagram, Model 880
624204 Schematic Diagram, Dual Alarm
624251 Schematic Diagram, Isolated Remote Control
624599 Schematic Diagram, Auto Zero/Span Control
)
VI
Rosemount Analytical
July 1998
748176-N
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REFACE
SAFETY SUMMARY
To avoid explosion, loss of life, personal injury and damage to this equipment and
on-site property, all personnel authorized to install, operate and service the Model 880
Non-Dispersive Infrared Analyzer should be thoroughly familiar with and strictly follow
the instructions in this manual. Save these instructions.
DANGER is used to indicate the presence of a hazard which will cause severe
personal injury, death, or substantial property damage if the warning is ignored
WARNING is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
NOTE is used to indicate installation, operation, or maintenance information which is
important but not hazard-related.
WARNING: ELECTRICAL SHOCK HAZARD
Do not operate without 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 VAC, 50/60
Hz electric power. For operation on 230 VAC, 50/60 Hz electrical power, see
Section 2.3 for modifications.
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July 1998
Rosemount Analytical
P-1
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ODEL
880 NON-D
ISPERSIVE INFRARED ANALYZER
!
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 Section 2.8.
Internal leaks resulting from failure to observe these precautions could result in
an explosion causing death, personal injury or property damage.
WARNING: POSSIBLE EXPLOSION HAZARD
WARNING: PARTS INTEGRITY
!
Tampering or unauthorized substitution of components may adversely affect
safety of this product. Use only factory documented components for repair
!
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.
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.
!
This analyzer requires periodic calibration with known zero and standard gases.
Refer to Sections 2.6, 3.7, 3.9, 3.10 and 3.11. See also General Precautions for
Handling and Storing High Pressure Cylinders, following Section 7.
CAUTION: TOPPLING HAZARD
CAUTION: HIGH PRESSURE GAS CYLINDERS
P-2
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July 1998
748176-N
REFACE
P
S
PECIFICATIONS
C
ATALOG NUMBERS
191809 Standard Case
191810 Extended Case
POWER REQUIREMENTS:
115/230 VAC ±10%, 50/60 ±3 Hz, 150 W; 350 W with optional case heater
O
PERATING TEMPERATURE
32°F to 113°F (0°C to 45°C)
Some configuration may require optional case heater
DIMENSIONS:
8.7 in (22.0 cm) H x 19 in. (483 mm) W x 19 in. (483 mm) D, standard case
8.7 in (22.0 cm) H x 19 in. (483 mm) W x 24 IN. (610 MM) D, extended case
WEIGHT:
56 lbs (25 kg), standard case
68 lbs (31 kg), extended case
R
EPEATABILITY
1% of fullscale
N
OISE
:
1% of fullscale
1
:
:
:
Z
ERO DRIFT
:
±1% of fullscale per 24 hours
S
PAN DRIFT
:
±1% of fullscale per 24 hours
R
ESPONSE TIME
: (E
LECTRONIC
)
Variable, 90% of fullscale in 0.5 sec to 20 sec, field selectable
S
ENSITIVITY
:
100 ppm fullscale carbon monoxide at atmospheric pressure
50 ppm fullscale carbon dioxide at atmospheric pressure
S
AMPLE CELL LENGTH
:
0.04 in. (1 mm) to 15.0 in. (381 mm)
M
ATERIALS IN CONTACT WITH SAMPLE
W
INDOWS
C
ELLS
T
UBING
F
ITTINGS
O-R
:
INGS
Sapphire, quartz, Irtran
:
Gold plated Pyrex or stainless steel
FEP Teflon
:
316 stainless steel
:
Viton-A
:
:
2
1
Performance specifications based on ambient temperature shifts of less than 20°F (11°C) per hour.
2
Application dependent.
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SPECIFICATIONS (CONTINUED)
SAMPLE PRESSURE:
Max 10 psig (69 kPa), standard
Pressurized application available upon request
A
NALOG OUTPUT
:
Standard: 0 to 5 VDC
Optional: 0 to 20 mA/4 to 20 mA
L
INEARIZATION
:
Keypad entered coefficients for linearizing 1, 2 or all 3 ranges
ENCLOSURE:
General purpose for installation in weather-protected area.
Optional purge kit per Type Z, ANSI/NFPA 496-1989.
3
3
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. Analyzes 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.
P-4
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July 1998
748176-N
S
PECIFICATIONS - OPTIONS
A
LARM
R
ELAY OUTPUTS
Two single point, field programmable high or low, deadband up
:
to 20% of fullscale.
Two form C contacts rated 3A-125/250 VAC or 5A-30 VDC
(resistive)
CAL GAS CONTROL
RELAY OUTPUTS:
Two front panel actuated contact closures
Two form C contacts rated 3 A, 125/250 VAC or 5 A, 30 VDC
(resistive)
A
UTO ZERO/SPAN
RELAY OUTPUTS:
Four contact closures, field programmable frequency and
duration of closure. Two contact closures for indication of
insufficient zero and span adjustment.
Four form C contacts rated 3A-125/250 VAC or 5A-30 VDC
(resistive),
Two form A contact rated (resistive load):
Max switching power: 10 Watts
Max switching voltage: 30 VDC
Max switching current: 0.5 A
REFACE
P
R
EMOTE
I/O
R
ELAY OUTPUTS
I
NPUTS
Three remotely changeable ranges with positive identification.
:
Binary or decimal 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
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July 1998
Rosemount Analytical
P-5
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ODEL
880 NON-D
ISPERSIVE INFRARED ANALYZER
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE
For order administration, replacement Parts, application assistance, on-site or factory
repair, service or maintenance contract information, contact:
Rosemount Analytical Inc.
Process Analytical Division
Customer Service Center
1-800-433-6076
RETURNING PARTS TO THE FACTORY
Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call: Model Number, Serial Number, and Purchase Order Number or Sales Order
Number.
Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sender, freight collect.
When returning any product or component that has been exposed to a toxic, corrosive
or other hazardous material or used in such a hazardous environment, the user must
attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification
that the material has been decontaminated, disinfected and/or detoxified.
Return to:
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
TRAINING
A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the Current Operator and Service Training Schedule contact
the Technical Services Department at:
Rosemount Analytical Inc.
Phone: 1-714-986-7600
FAX: 1-714-577-8006
D
OCUMENTATION
The following Model 880 Non-Dispersive Infrared Analyzer instruction materials are
available. Contact Customer Service or the local representative to order.
P-6
748176 Instruction Manual (this document)
Rosemount Analytical
July 1998
748176-N
REFACE
P
Q
UICK STARTUP AND TROUBLESHOOTING GUIDE
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.
The purpose of this guide is to give quick and simplified instructions on getting started.
Some of the non-critical details may have been left out. Refer to the appropriate section in
this manual for complete descriptions of all procedures. Read this guide completely before
starting up the analyzer. This guide contains step-by-step instructions for startup and
includes information helpful in simplifying some procedures detailed in the manual. The
analyzer has been setup and tested at the factory per the specified sales order. Generally
the only settings and adjustments required are calibration gas values, zero/span
calibrations, and adjustments on option boards. Refer to the appropriate section in the
manual for information on option boards.
OW TO USE THIS GUIDE
H
First, read Section 1, Introduction and install analyzer per Section 2 of this manual.
Familiarize yourself with Keypad Operation. Step through Mode Functions. Go to Section
3, Initial Startup and continue (in sequence) through this guide.
CONTENTS
GAS REQUIREMENTS......................................................................................P-8
DISPLAYS ......................................................................................................P-8
FRONT PANEL KEYPAD...................................................................................P-9
MODE FUNCTION ............................................................................................P-10
INITIAL STARTUP..............................................................................................P-10
Range Mode ......................................................................................P-10
Range Number ......................................................................................P-10
Gain=1, 2, 4 or 8......................................................................................P-10
LINEARIZATION MODE.....................................................................................P-12
DIAGNOSTICS MODE.......................................................................................P-12
Osc Tune ......................................................................................P-12
Det Sig (with zero gas flow) .....................................................................P-12
DET SIG (with span gas flow) ..................................................................P-12
SCR CUR ......................................................................................P-12
ZERO CALIBRATION.........................................................................................P-13
SPAN CALIBRATION.........................................................................................P-14
SOURCE BALANCE ADJUSTMENT .................................................................P-14
SOURCE ALIGNMENT ......................................................................................P-15
TROUBLESHOOTING .......................................................................................P-15
TROUBLESHOOTING CHART..........................................................................P-17
COMPONENTS LOCATION...............................................................................P-19
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July 1998
Rosemount Analytical
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ODEL
880 NON-D
ISPERSIVE INFRARED ANALYZER
GAS REQUIREMENTS
Zero - Use a gas containing less than 25% of the measured component, preferably 0%.
Span - Use a gas containing from 51 to 100% of the measured component, for each range.
80 to 100% is recommended. If calibration is attempted with a span gas less than 51% of
the measured component, an error message will be displayed.
DISPLAYS
RUN M
ODE
ZERO M
Concentration, Engineering Units, or % Fullscale.
If Linearization ON, reads in engineer ing units. If
Linearization OFF, reads in % Fullscale.
XXX % ABC L1
XXX ppm ABC L2
XXX %FS ER4 R3
Code for measured component or
Error Message
ODE
ZERO PS=X.X%
ZR=X.X PS=X.X%
Local, or Remote Control, Range 1, 2 or 3.
% of ZERO potentiometer used
(Hardware pot)
P-8
Present RUN Mode value
SPAN M
Rosemount Analytical
ODE
Present RUN Mode value
SPAN PS=X.X%
XXX NN% MMM
% of SPAN potentiometer
used (Hardware pot)
July 1998
% of ZERO potentiometer used
(Hardware pot)
% of SPAN potentiometer used
(Hardware pot)
Calibration Span gas value
entered by user while in RANGE
Mode.
Calibration Gas value displayed
if Linearizer is OFF.
748176-N
REFACE
P
FRONT PANEL KEYPAD
The following flow diagram describes the basic functions of the f ront panel keypad, starting
in RUN mode. Flow diagrams for other operations are located in this guide and Section 3.
MODE
MODE
Press ENTER to select
the displayed mode.
MAIN MENU SELECTIONS
ZERO
Press SHIFT + ENTER to abort
ZERO and return to RUN mode
ENTER
ZERO
SHIFT
Press or to change
values up or down.
SHIFT
Press and to make large
jumps horizontally from one display to
the next.
ZERO CAL.
ZERO PS=XX%
ENTER
ENTER
ENTER
ZR=X.X PS=XX%
Press ENTER again to calculate
ZERO and return to RUN mode
ENTER
Press to store in permanent
memory the screen values for the
displayed mode.
SHIFT
Press and to return to
RUN mode.
Press or to change
values up or down.
ENTER
SPAN
SPAN
Press SHIFT + ENTER to abort
SPAN and return to RUN mode
SHIFT
RUN Mode
SPAN CAL.
SPAN PS=XX%
ENTER
ENTER
ENTER
RUN Mode
Press or to change
values up or down.
XX.X XX% XX.X
Press ENTER again to calculate SPAN
(software SPAN) and return to RUN mode
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July 1998
Rosemount Analytical
P-9
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ODEL
880 NON-D
ISPERSIVE INFRARED ANALYZER
MODE FUNCTION
MODE
SECURITY
RANGE
DIAGNOSTICS
LINEARIZER
ALARM
CURRENTM
AUTO-CAL
Press to enter displayed mode.
Press and to return to RUN mode.
ENTER
SHIFT ENTER
REMOTE IN/OUT
INITIAL STARTUP
RANGE M
As a first step, check range mode settings and enter your calibration gas values. See
Range Mode flow diagram on following page.
ANGE NUMBER
R
Setup desired operating range (1, 2 or 3) using up and down arrow keys. Remember to
press ENTER after changing values to store data.
AIN
G
=1, 2, 4
Don't change from factory setting at this time. If it becomes necessary to make a change
during calibration, use the following table as a guide:
ODE
OR
8
DIGITAL GAIN SETTINGS
DETECTOR SIGNAL (DET SIG) GAIN SETTING
<=7.5 V and >4 V 1
<=4 V and >2.2 V 2
<=2.2 V and >15 V 4
<=1.5 V 8
P-10
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July 1998
748176-N
REFACE
P
Note
The detector signal voltages can be observed in the DIAGNOSTICS mode.
Some deviations from these recommended settings are permissible, if the
instrument can't be spanned keeping the %PS reading between 5% and 95%.
Additional information on the gain setting is located in Section 5.7.
MODE
RANGE 1
Set to 1, 2, 4 or 8 (see table
under Digital Gain Settings)
Fullscale range in % or ppm
SECURITY
RANGE
ENTER
RANGE 2 RANGE 3 CMP ABC
SHIFT
GAIN=X
SHIFT
FS=XX % or ppm
SHIFT
ENTER
ENTER
Take %FS value from non-linear
CAL GAS=XXX.X %FS
calibration curve
Zero Gas Offset as a % of
fullscale
Time Constant: 0.5 to 20 sec.
ZR. OFFSET=0.00 %FS
TIME CONST=XX
Move one character at a time. If last character,
moves to next screen.
SHIFT
ENTER
Move one screen at a time.
Press to store, accept
ENTER
SHIFT
ENTER
SHIFT
748176-N
July 1998
Rosemount Analytical
P-11
M
ODEL
880 NON-D
ISPERSIVE INFRARED ANALYZER
LINEARIZATION MODE
Verify that LINEARIZER ON/OFF is in the desired position.
Verify the analyzer coefficients for each range against the values supplied on the factory
calibration sheet in the rear of this manual.
Note
The linearizer range positions 1, 2 and 3 allow setting coefficients for these ranges.
When the operating range is selected from the "Range" mode, the correct
coefficients for that range will be selected regardless of which linearization range
settings (1, 2 or 3) was used in the linearization mode. Linearization position A is an
"ALL" range position, using coefficients from range 3 for all ranges. Position A can
only be used if the range to range ratio is equal to or less than 3:1.
DIAGNOSTICS MODE
If the display is unstable (oscillating) in OSC, TUNE, DET SIG and/or SCR CURRENT,
there probably is an ER4 error message. Refer to the Troubleshooting chart.
OSC TUNE - Tune to 75 to 80% of maximum. Turn counterclockwise from maximum.
DET SIG (
WITH ZERO GAS FLOW
) - Must be between 0.4 to 1.2 volts. If <0.4 volts: Re-
adjust source balance per Section 3.5. If >1.2 volts: See Troubleshooting Chart, Source
Balance and Source Alignment.
DET SIG (
WITH SPAN GAS FLOW
) - Adjust detector signal voltage with GAIN potentiometer
R3 on the Signal Board (see Drawing 624055 in the rear of this manual). For Range 3
(least sensitive) adjust this voltage as close to 7.5 volts as possible. Do not exceed 7.5
volts. Must be between 0.4 to 1.2 volts. For low ppm applications the maximum attainable
voltage may be considerably below 7.5 volts. If span gas is less than 100% fullscale, the
detector voltage should be set roughly equal to (7.5 volts) X (% fullscale read off of the nonlinear curve)/100.
Detector signal voltages with span gas flowing will dictate the digital GAIN settings. (see
table under Range Mode, Gain.)
SRC CUR - Adjust Source Current with R9 on the Power Supply Board. Source current
will be between 700 to 950 mA. The source will have a longer life on lower currents.
Current setting will be lower on high concentration, short cell path applications, such as %
level measurements. Will be higher on low concentration, long cell path measurements,
such as 0 to 10 ppm CO2.
P-12
Rosemount Analytical
July 1998
748176-N
REFACE
P
MODE
75 to 80% of maximum.
De-tuned in counterclockwise direction.
0.4 to 1.2 volts with zero gas flow.
1.2 to 7.5 volts with span gas flow.
7.5 volts maximum on highest range.
Must be between 700 and 950 mA.
700 to 800 mA for % to high ppm ranges.
800 to 950 mA for mid to low ppm.
SECURITY
RANGE
DIAGNOSTICS
OSC TUNE
DET SIG
SRC CUR
SHIFT
ENTER
RUN MODE
ENTER
ENTER
ENTER
ENTER
ZERO CALIBRATION
There is one hardware zero for all three ranges, and three software zeros, one for each
range. Once the hardware zero has been adjusted for one of the ranges, IT SHOULD NOT
BE CHANGED when doing software zero on the other two ranges. See flow chart below.
If problems are encountered, such as error messages (ER0, ER1, ER2, ER3 or ER4) go to
DIAGNOSTICS mode to locate the cause of the problem. Use the Troubleshooting chart in
this section, as well as Section 5, Troubleshooting.
ZERO
Using up/down arrow keys, adjust hardware
zero (ZR=X.X) close to zero. Does not
have to be exactly zero.
Calculates software zero, then returns to
RUN mode.
ZERO PS=XX%
ZR=X.X PS=XX%
CALCULATING ZERO
XXX% or ppm ABC L3
RUN MODE
PS stands for % of digital potentiometer used.
ENTER
Limits are 5 to 95%.
Press ENTER before adjusting.
ENTER
Note: Use up/down arrow keys on one range only. Take a software zero on the other ranges.
748176-N
July 1998
Rosemount Analytical
P-13
M
ODEL
880 NON-D
ISPERSIVE INFRARED ANALYZER
SPAN CALIBRATION
There are three hardware spans and three software spans. Use the flow diagram as a
guide.
If problems are encountered, such as error messages (ER0, ER1, ER2, ER3 or ER4) go to
DIAGNOSTICS mode to locate the cause of the problem. Use the Troubleshooting chart in
this section, as well as Section 5, Troubleshooting.
SPAN
XX.X = Actual reading in ppm, % or %FS.
XX% = Percent of span potentiometer.
XX.X = Span gas engineering units or nonlinear value taken from curve.
Calculates software zero, then returns to
RUN mode.
See Troubleshooting if error message appears.
SHIFT+ENTER will abort function and return to RUN mode.
OURCE BALANCE ADJUSTMENT
S
SPAN 3 PS=XX%
XX.X XX% XX.X
CALCULATING SPAN
XXX% or ppm ABC L3
RUN MODE
PS stands for % of digital potentiometer used.
ENTER
Limits are 5 to 95%.
Press ENTER before adjusting.
ENTER
Adjust hardware span with up/down arrow keys.
Adjust until actual reading is close to, but less than
non-linear value. Non-linear value must be over 51%
of fullscale and must be <= fullscale range. Up/down
arrow keys can be adjusted for all three ranges before
taking software span.
This procedure should not be necessary on a new analyzer unless problems are
encountered.
1. Access the DET SIG display in DIAGNOSTICS mode.
2. Flow zero gas through the sample cell for a minimum of two minutes.
3. Slightly loosen the hex standoff on the sample cell adjust screw.
4. Rotate the shutter adjust screw until a minimum reading is obtained.
5. Add 0.4 to 0.5 volts to this reading. If this reading exceeds 1.2 volts, a source alignment
is required.
6. Rotate the shutter adjust screw clockwise until the display reads the value obtain in step
5.
7. Re-tighten the hex standoff. Verify that the display does not change.
8. Close analyzer. Allow one hour for analyzer readings to stabilize. If zero gas reading
has changed appreciably, re-balance the analyzer.
P-14
Rosemount Analytical
July 1998
748176-N
REFACE
P
OURCE ALIGNMENT
S
Source balance adjustment must be performed prior to source alignment.
This procedure is necessary when the detector signal is greater than 1.2 volts after step 5 in
the source balance adjustment procedure.
1. Connect a DVM between TP6 and TP2 on the Signal Board.
2. Set the source balance screw halfway in. (1/2 inch of the threads are visible.)
3. Loosen the two screws holding each source in place.
4. Adjust both measurement and reference sources up and down to reach the minimum
detector signal. Tighten screws.
5. Perform source balance adjustment procedure above.
ROUBLESHOOTING
T
If problems are encountered, such as error messages ER0, ER1, ER2, ER3 or ER4, go to
the DIAGNOSTICS mode (page P-12) to assist in locating the cause of the problem.
Use the following Troubleshooting Chart as well as Section 5 Troubleshooting.
SPAN GAS ERRORS ER1, ER2 OR ER3
Check RANGE, CAL GAS, CL GAS
• CAL GAS (Span gas) must be <=FS (fullscale range).
• Span gas must be 51 to 100% of the fullscale range.
• CL GAS must be read off of the non-linear curve.
• The RUN mode concentration reading must be less than the CL GAS value. (See SPAN
Mode Display flow diagram, page P-8)
Note
Spanning with Linearizer ON
If spanning with linearizer ON, RUN MODE values will be in engineering units, and
CAL GAS values will appear in the right-side display.
The microprocessor will be using the non-linear values for the initial stages of
calibration. It may calculate a CAL GAS value that is higher than the entered value.
An error message will be displayed if this occurs.
748176-N
July 1998
Rosemount Analytical
P-15
ODEL
M
880 NON-D
NY OF THE FOLLOWING MAY CORRECT THE PROBLEM
A
ISPERSIVE INFRARED ANALYZER
:
1. Re-check CAL GAS and CL GAS values entered in RANGE mode.
2. Verify that the NON-LINEAR curve is read for CL GAS entry.
3. During hardware span adjust, make the run value lower than the CAL value.
4. Re-calibrate with the linearizer OFF.
RUN M
ODE VALUE TOO LOW DURING HARDWARE
SPAN
ADJUSTMENT
Hardware potentiometer is adjusted to 95% and RUN Mode value still too low;
• Check SPAN GAS bottle for correct concentration and flow
• Check for leaks
• Check DET SIG adjustments
• Check DIGITAL GAIN adjustments
RUN M
ODE VALUE TOO HIGH DURING HARDWARE
SPAN
ADJUSTMENT
Hardware potentiometer is adjusted to 5% and RUN Mode value still higher than CL
or CAL GAS display when software zero taken by pressing ENTER the error
message appears.
• Check SPAN GAS bottle for correct concentration and flow
• Check DET SIG adjustments
• Check DIGITAL GAIN adjustments
P-16
Rosemount Analytical
July 1998
748176-N
REFACE
P
ROUBLESHOOTING CHART
T
Prior to troubleshooting, verify that OSC TUNE (oscillator tune) is properly adjusted. If
reading is oscillating (and can't be correct by OSC TUNE adjustment), check DET SIG and
digital GAIN adjustment.
ZERO
ER0
Run ZERO Calibration (page P-13), re-adjust hardware zero
Are you unable to adjust any further (at PS=5 or 95% limits)?
Have you tried adjusting the RUN mode reading (changing the hardware zero
potentiometer) but are unable to bring the reading close enough to zero?
When ENTER is pressed to calculate software zero, does ER0 error message
appear?
YES
Is DET SIG >1.2 volts? Is DET SIG <0.4 volts?
YES
NO
NO
Check test points with
DVM. Replace boards.
Is application for CO2 and is CO2 range <= 20 ppm @ 1 atmospheric
pressure? (Reads negative, then positive on upscale gas.)
NO
YES
Is CO2 free purge connected and
flowing for reference cell and
NO
source shroud?
Connect CO2 free purge with 10
YES
psig pressure.
Check flow, should be 50 cc/min.
Re-balance Sources
YES
748176-N
Can't get DET SIG below 1.2 V Re-align Sources
YES
July 1998
Rosemount Analytical
P-17
M
ODEL
880 NON-D
ISPERSIVE INFRARED ANALYZER
ER4
Digital error - Generally caused by combination of too high an analog signal for the digital
gain setting used.
Check DET SIG with span gas flowing.
Are readings too unstable to read (oscillating)?
YES
Check both OSC TUNE and SRC
CURRENT in DIAGNOSTICS
mode (page P-12).
Are readings oscillating?
YES
Connect a DVM to TP2 (detector
signal) and TP6 (ground).
Check/adjust analog detector
signal gain, R3 (page P-10)
Re-Zero (page P-8)
NO
Read DET SIG in DIAGNOSTICS
mode (page P-12)
P-18
Re-Span (page P-8)
Rosemount Analytical
July 1998
748176-N
REFACE
P
EADS WRONG WAY ON UPSCALE GAS
R
Reads downscale, then upscale on low flows of upscale gas (the n egative swing might
be missed if flow is too fast)
This is caused by imbalance in reference/measuring energy to detector.
• Check for purge for <= 20 ppm CO2 applications
• Check source balance (page P-14)
OMPONENT LOCATION
C
Display Contrast
Adjust
R8
Reset
SW1
Micro Board
Power Supply
Gain Adjust
R3
Signal Board
Source Current
Adjust
R9
Oscillator Tune
Detector Module
Option
Boards
Motor/Source
Source Balance
Adjust and Locknut
748176-N
July 1998
Rosemount Analytical
P-19
ODEL
M
N
OTES
880 NON-D
ISPERSIVE INFRARED ANALYZER
P-20
Rosemount Analytical
July 1998
748176-N
I
NTRODUCTION
1
1.1 DESCRIPTION
The Model 880 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, backlit 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.
By turning the linearizer ON and entering linearizing coefficients, a calibration curve
may be used to convert display or recorder readings into linearized engineering units.
When this f eature is ON, the analyzer utilizes a linearizing function for linear readout
of concentration values on the display and on a recorder. A diagnostics mode is
provided as standard.
1.2 AVAILABLE OPTIONS
Operation of the Model 880 can be enhanced with the choice of several options:
UAL ALARMS
D
User-set dual alarms are available with configurable HI/LO designations and
deadband.
SOLATED CURRENT OUTPUT
I
For normal usage, the 0 to 20 mA or 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.
748176-N
July 1998
Rosemount Analytical
1-1
M
ODEL
880 NON-D
ALIBRATION GAS CONTROL
C
ISPERSIVE INFRARED ANALYZER
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
R
I/O
An optional remote range input/output 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.
1-2
Rosemount Analytical
July 1998
748176-N
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