Rosemount Manual: MicroCEM TS Analysis Enclosure-Rev 2.37 | Rosemount Manuals & Guides

PREFACE

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Micro Continuous Emission Monitor

Operation & Maintenance Manual

Revision 2.37, Jan. 31, 2005

Part Number 1021021-100

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Rosemount Analytical µCEM Continuous Analyzer Transmitter i

PREFACE

Table of Contents

PREFACE..............................................................................................................................................vi

Intended Use Statement......................................................................... .................. .............................vi

Safety Summary....................................................................................................................................vi

Specifications - Analysis Enclosure General.........................................................................................ix

Specifications – Probe/Sample Handling Enclosure: GENERAL .........................................................xi

Customer Service, Technical Assistance and Field Service.........xii

1. Introduction ........................................................................1–1

1.1 Overview.......................................................................................................................... 1–1

1.2 Time Shared Option......................................................................................................... 1–3

1.3 Theory of Operation......................................................................................................... 1–4

1.3.1 NOx..................................................................................................................................1–4

1.3.2 CO ...................................................................................................................................1–4

1.3.3 O2....................................................................................................................................1–4

1.3.4 SO2..................................................................................................................................1–5

2. Detector Methodologies.....................................................2–1

2.1 Non-Dispersive Infrared (NDIR).......................................................................................2–1

2.1.1 Interference Filter Correlation Method.............................................................................2–1

2.1.2 Opto-Pneumatic Method..................................................................................................2–2

2.1.3 Overall NDIR Method.......................................................................................................2–4

2.2 Paramagnetic Oxygen Method........................................................................................ 2–5

2.3 Electrochemical Oxygen Method..................................................................................... 2–6

3. Installation ..........................................................................3–1

3.1 Specifications................................................................................................................... 3–1

3.2 Process and Calibration Gas Connection........................................................................ 3–9

3.2.1 Gas Conditioning...........................................................................................................3–10

3.3 Installation...................................................................................................................... 3–11

3.3.1 Location.........................................................................................................................3–11

3.3.2 Limitations......................................................................................................................3–11

3.3.3 Mounting Options...........................................................................................................3–11

3.3.4 Electrical Connections...................................................................................................3–11

3.3.4.1 Circular Connector Assembly Instructions..................................................................... 3–13

3.3.4.2 EXT I/O Interface Connector (J5) MicroCEM inputs and outputs are specific for customer

use...................................................................................................................................................3–14

3.3.5 Analytical Leak Check ...................................................................................................3–24

3.3.5.1 Flow Indicator Method ................................................................................................... 3–27

3.3.5.2 Manometer Method........................................................................................................ 3–28

4. Startup and Operation.. ................ .............................. ........ 4-1

4.1 Startup Procedure.............................................................................................................4-1

4.2 Analyzer Operation........................... ................... .................. ................. .................. ........ 4-2

4.2.1 Pocket PC User Interface.................................................................................................4-2

4.2.2 µCEM Main Window.........................................................................................................4-3

4.2.3 µCEM Menus....................................................................................................................4-5

4.2.4 µCEM Alarms....................................................................................................................4-7

4.2.5

4.2.6 µCEM Login-Current User Indication..............................................................................4-10

4.2.7 Time Share Switching Control Option.............................................................................4-11

4.3 µCEM Settings................................................................................................................4-12

4.3.1 µCEM Settings-Range....................................................................................................4-12

µ

CEM Login......................................................................................................................4-9

PREFACE

4.3.2 µCEM Settings-Auto Calibration.....................................................................................4-13

4.3.3 µCEM Settings - Auto Calibration Time and Frequency.................................................4-14

4.3.4 µCEM Settings-Limits.....................................................................................................4-15

4.3.5 µCEM Settings-Calibration Gas......................................................................................4-16

4.3.6 µCEM Settings-Maintenance Mode................................................................................4-18

4.3.7 µCEM -Manual Calibration..............................................................................................4-19

4.3.8 Auto Calibration..............................................................................................................4-20

4.4 µCEM Administration......................................................................................................4-21

4.4.1 µCEM Administration-User Settings...............................................................................4-21

4.4.2 µCEM Administration-Auto Logoff ..................................................................................4-22

4.5 µCEM Factory and User Settings...................................................................................4-23

4.6 uCEM Data Logs .................................................................. .................. ................... ..... 4-26

4.6.1 Maximum Log File Size ..................................................................................................4-26

4.6.2 Maximum Number of Log Files.......................................................................................4-26

4.6.3 Log File Name Format....................................................................................................4-26

4.6.4 Measurement Log File Format........................................................................................4-26

4.6.5 Calibration Log File Format ............................................................................................4-27

4.6.6 Alarm Log File Format....................................................................................................4-29

4.6.7 Accessing the Real-Time ACSII Data String via Ethernet TCP/IP (DAS).......................4-31

4.7 Viewing Data via the Pocket PC Web Browser ..............................................................4-34

4.8 Viewing µCEM Data with an external PC Web Browser.................................................4-38

4.8.1 Real-Time Page..............................................................................................................4-40

4.8.2 Emissions Page..............................................................................................................4-41

4.8.3 Download Page ..............................................................................................................4-44

4.9 Viewing µCEM Data with MS Excel................................................................................4-45

5. Maintenance and Service................................................... 5-1

5.1 Overview...........................................................................................................................5-1

5.2 Converter..........................................................................................................................5-2

5.3 Ozonator...........................................................................................................................5-2

5.4 Personality Modules ............................................................. ................... ......................... 5-2

5.5 Detector Assembly............................................................................................................ 5-2

5.6 Central Processing Unit....................................................................................................5-5

5.6.1.1 Features............................................................................................................................5-5

5.6.1.2 EMBEDDED ENHANCED BIOS:...................................................................................... 5-6

5.6.2 Analog/Digital I/O Board...................................................................................................5-7

5.6.2.6 Analog Outputs...............................................................................................................5-10

5.6.2.7 FIFO and 16-Bit Bus Interface........................................................................................5-11

5.6.2.8 Specifications..................................................................................................................5-11

5.6.3 PCMCIA Adapter............................................................................................................5-12

5.6.3.1 Features..........................................................................................................................5-13

5.6.3.2 SOFTWARE FEATURES:..............................................................................................5-13

5.6.4 Modem............................................................................................................................5-14

5.6.4.1 Features..........................................................................................................................5-14

5.6.5 Flash Drive......................................................................................................................5-15

5.6.5.1 Specifications..................................................................................................................5-15

5.6.6 Compact Flash................................................................................................................5-18

5.6.6 Pocket PC.......................................................................................................................5-20

5.6.7 Wireless LAN Adapter ....................................................................................................5-21

5.6.8 500 Watts Power Supply ................................................................................................5-22

5.6.8.1 FEATURES.....................................................................................................................5-22

5.7 Replacement Parts.........................................................................................................5-23

5.7.1 Replacement Part list......................................................................................................5-23

5.8 System Enclosure...........................................................................................................5-28

5.8.1 uCEM in a 24" x 20" x 12" Fiberglass Enclosure............................................................5-28

PREFACE

5.8.2 uCEM in a 24" x 24" x 12" Fiberglass Enclosure............................................................5-29

5.8.3 uCEM in a 24" x 20" x 12" Stainless Steel Enclosure.....................................................5-30

5.8.4 uCEM in a 24" x 36" Panel Mount configuration.............................................................5-30

5.9 Trouble LED....................................................................................................................5-31

6. µCEM Software........................................................... ........ 6-1

6.1 µCEM User Interface Software.........................................................................................6-1

6.2 µCEM Web Server Software.............................................................................................6-1

6.3 Software Development Management ...............................................................................6-2

6.4 µCEM Pocket PC Connection Failure...............................................................................6-3

Table of Figures

Figure 1-1. µCEM Micro Continuous Emission Monitoring – Analysis Enclosure……………….…1-1
Figure 1-2. µCEM Micro Continuous Emission Monitoring Gas Analyzer with Time Share
option……………………………………………………………………………………………….…1-2
Figure 1-3. Time Share option Flow Diagram………………………………………………….…….1-3
Figure 2-1. Absorption Bands of Sample Gas and Transmittance of Interference Filters……………2-2
Figure 2-2. Opto-Pneumatic Gas Detector……………………………………………………………2-3
Figure 2-3. Overall NDIR Method……………………………………………………………………2-4
Figure 2-4. Electrochemical Oxygen Sensor………………………………………………………….2-6
Figure 2-5. Reaction of Galvanic Cell………………………………………………………………..2-7
Figure 3-1. Dimensional Drawing, Door closed……………………………………………………...3-2
Figure 3-2. Dimensional Drawing, Door closed……………………………………………………...3-3
Figure 3-3. Basic Installation Guideline……………………………………………………………...3-4
Figure 3-4. Basic Installation Guideline – Time Share Option……………………………………….3-5
Figure 3-5. Standard System Flow diagram…………………………………………………………..3-6
Figure 3-6. System Flow Diagram – Optional Time Share…………………………………………..3-7
Figure 3-7. Analysis Enclosure Internal Gas flow Diagram………………………………………….3-8
Figure 3-8. Gas Connections………………………………………………………………………...3-10
Figure 3-9. Electrical Connections…………………………………………………………………..3-12
Figure 3-10. External Electrical Connections……………………………………………………….3-12
Figure 3-11. Circular Connector Assembly Instructions……………………………………………3-13
Figure 3-12. illustrates MicroCEM analysis enclosure……………………………………………...3-17
Figure 3-13. Backplane Assembly Drawing………………………………………………………...3-20
Figure 3-14. Backplane Assembly Photo……………………………………………………………3-21
Figure 3-15. uCEM Analysis Enclosure Internal interconnect diagram…………………………….3-22
Figure 3-16. Leak Test Flow Method……………………………………………………………….3-23
Figure 3-17. Leak Test Manometer Method………………………………………………………...3-24
Figure 4-1. uCem Main Display……………………………………………………………………...4-4
Figure 4-2.1 uCEM File Menu……………………………………………………………………….4-5
Figure 4-2.2 uCEM Tools Menu……………………………………………………………………...4-6
Figure 4-2.3 uCEM Advanced Menu…………………………………………………………………4-6
Figure 4-3. Pocket PC Alarms Screen………………………………………………………………...4-7
Figure 4-4. uCEM Login……………………………………………………………………………...4-9
Figure 4-5. Current User Indication…………………………………………………………………4-10
Figure 4-6. Range Settings…………………………………………………………………………..4-12
Figure 4-7. Auto Calibration Settings……………………………………………………………….4-14
Figure 4-8. Auto Calibration Time and Frequency………………………………………………….4-15
Figure 4-9. Limit Settings…………………………………………………………………………...4-16
Figure 4-10. Calibration Gas Settings……………………………………………………………….4-18
Figure 4-11. Maintenance Mode Settings…………………………………………………………...4-19

PREFACE

Figure 4-12. Manual Calibration Menu……………………………………………………………..4-20
Figure 4-13. Auto Calibration Status Screen………………………………………………………..4-21
Figure 4-14. Manual Calibration Results……………………………………………………………4-21
Figure 4-15. User Settings…………………………………………………………………………...4-22
Figure 4-16. Auto Logoff……………………………………………………………………………4-23
Figure 4-17. Temperature Control Dagnostics………………………………………………………4-36
Figure 4-18. View Data Logs………………………………………………………………………..4-37
Figure 4-19. View Data Logs Table…………………………………………………………………4-38
Figure 4-20. Illustration of IP Address Screen………………………………………………………4-39
Figure 4-21. Illustration of Explorer Screen………………………………………………………...4-40
Figure 4-22. Real-Time Web Page…………………………………………………………………..4-41
Figure 4-23. Emissions Selection……………………………………………………………………4-42
Figure 4-24. emissions Table………………………………………………………………………..4-43
Figure 4-25. Calibration Table………………………………………………………………………4-44
Figure 4-26. Download Web Page…………………………………………………………………..4-45
Figure 5-1. Converter Assembly……………………………………………………………………...5-2
Figure 5-2. Detector Assembly……………………………………………………………………….5-4
Figure 5-3. CPU PCM-5896…………………………………………………………………………5-5
Figure 5-4. CPU Little Board 700……..…………………………………………………………….5-6
Figure 5-5. Compact Flash Card……………………………………………………………………...5-8
Figure 5-6. ADIO Board…………………………………………………………………………….5-10
Figure 5-7. ADDA Board……………………………………………………………………………5-10
Figure 5-8. ADIO Block Diagram…………………………………………………………………..5-11
Figure 5-9. PCMCIA Interface……………………………………………………………………...5-14
Figure 5-10. Modem…………………………………………………………………………………5-15
Figure 5-11. 256MB Flash Drive……………………………………………………………………5-17
Figure 5-12. Pocket PC……………………………………………………………………………...5-20
Figure 5-13. Wireless LAN adapter…………………………………………………………………5-21
Figure 5-14. 500 Watts Power Supply………………………………………………………………5-22
Figure 5-15. uCEM Analyzer with door open – Front View………………………………………..5-23
Figure 5-16. uCEM Enclosure with door open……………………………………………………...5-29
Figure 6-1. uCEM software Block Diagram………………………………………………………….6-1

Table of Tables

Table 3-1. EXT I/O Terminal Assignments…………………………………………………………………...3-14
Table 3-2. Sample Handling Unit Terminal Assignments…………………………………………………….3-16
Table 3-3. COM Interface Terminal Assignments…………………………………………………………….3-18
Table 3-4. LAN Interface Terminal Assignments……………………………………………………………..3-18
Table 3-5. CPU I/O Terminal Assignments…………………………………………………………………...3-19
Table 3-6. SSU Power Connection terminal Assignments……………………………………………………3-19
Table 3-7. AC Power Connection Terminal Assignments…………………………………………………….3-20
Table 4-1. Status Values………………………………………………………………………………………..4-4
Table 4-2. Alarm Summary…………………………………………………………………………………….4-7
Table 4-3. [General] Section…………………………………………………………………………………..4-25
Table 4-4. [Stream X] Section………………………………………………………………………………...4-26
Table 4-7. Measurement Log File Format…………………………………………………………………….4-28
Table 4-8. Calibration Log file Format………………………………………………………………………..4-28
Table 4-9. Alarm Log File Format…………………………………………………………………………….4-30
Table 5-1. Analog Inputs……………………………………………………………………………………….5-7
Table 5-2. Programmable Input Ranges………………………………………………………………………...5-8
Table 5-3. Analog Ouputs………………………………………………………………………………………5-8
Table 5-4. FIFO and 16-Bit Bus Interface……………………………………………………………………...5-9
Table 5-5. Replacement Part List…………………………………………………………..…………………..5-20

PREFACE

PREFACE

Intended Use Statement

The µCEM Continuous Emission Monitoring Gas Analyzer 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 applications.

Safety Summary

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.

DANGER: ALL PERSONNEL AUTHORIZED TO INSTALL,
OPERATE AND SERVICE THIS EQUIPMENT

To avoid explosion, loss of life, personal injury and damage to this equipment and on-site
property, do not operate or service this instrument before reading and understanding this
instruction manual and receiving appropriate training. Save these instructions.

If this equipment is used in a manner not specified in these instructions, protective systems
may be impaired.

WARNING: DEVICE CERTIFICATION(S)

Any addition, substitution, or replacement of components installed on or in this device, must
be certified to meet the hazardous area classification that the device was certified to prior to
any such component addition, substitution, or replacement. In addition, the installation of
such device or devices must meet the requirements specified and defined by the hazardous
area classification of the unmodified device. Any modifications to the device not meeting
these requirements, will void the product certification(s).

PREFACE

This device may contain explo sive, toxic or unhealthy gas components. Before clea ning or
changing parts in the gas paths, purge the gas lines with ambient air or nitrogen.

Do not open while energized. Do not operate without dome and covers secure. Installa tion
requires access to live parts which can cause death or serious injury.

DANGER: TOXIC GAS

+

WARNING: ELECTRICAL SHOCK HAZARD

POSSIBLE EXPLOSION HAZARD

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

WARNING: POSSIBLE EXPLOSION HAZARD

Ensure that all gas connections are made as labeled and are leak free. Improper gas
connections could result in explosion and death.

WARNING: TOXIC GAS

This unit’s exhaust may contain hydrocarbons and other toxic gases such as carbon
monoxide. Carbon monoxide is highly toxic and can cause headache, nausea, loss

consciousness, and death.

Avoid inhalation of the exhaust gases at the exhaust fitting.
Connect exhaust outlet to a safe vent using stainless steel or Teflon line. Check vent line and

connections for leakage.
Keep all tube fittings tight to avoid leaks. See Section 3.3.5 for leak test information.

of

PREFACE

WARNING: PARTS INTEGRITY AND UPGRADES

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

Because of the danger of introducing additional hazards, do not perform any unauthorized
modification to this instrument.

Return the instrument to a Rosemount Analytical Service office for service or repair to ensure
that safety features are maintained.

CAUTION: PRESSURIZED GAS

This unit requires periodic calibration with a known standard gas. It also may utilize a
pressurized carrier gas, such as helium, hydrogen, or nitrogen. See General Precautions for
Handling and Storing High Pressure Gas Cylinders at the rear of this manual.

CAUTION: HEAVY WEIGHT

U

SE TWO PERSONS OR A SUITABLE LIFTING DEVICE TO MOVE OR

CARRY THE INSTRUMENT

.

Specifications - Analysis Enclosure General

PREFACE

SPECIFICATIONS – Analysis Enclosure: GENERAL

Power: Universal Power Supply 85 – 125 VAC, 50 – 60 Hz, +
Nominal
MicroProcessor: Intel Pentium processor running at 266 MHz, or Intel Celeron processor running at 400MHz,
64MB RAM, PC/104 architecture, Windows NT embedded Platform

Pocket PC: 206MHz, StrongArm processor, 32MB RAM 32 ROM, 240 X 320 pixels LCD, TFT color, backlit,
Wireless LAN optional

Detectors//Number: NDIR (CO), NDIR2 (CO2), UV (SO2), Paramagnetic (O2), Electrochemical (O2),
Chemiluminscent (NOx) // Up to three in one analyzer

Mounting: Wall Mount or Panel Mount
Area Classification: General Purpose / NEMA 4X Fiberglass Enclosure Compliant or Stainless Steel Enclosure.
Compliance's: CSA (Pending)
Ambient Temperature Range: -30° to 50° Celsius.
Relative Humidity: 5 to 99%
Inputs/Outputs: The complete I/O list with terminal locations is located in section 3.3.4
Digital:

RS-485 Serial Port. (Multi-Drop Network)
RS-232 Serial Port.
LAN, Ethernet 10/100-BaseT

Connectivity Protocols:

HTML (Web Browser) – Status, file transfer Modem / Web browser
TCP/IP, MTTP ASCII String
Microsoft Shared drive
FTP Logs download
TELNET Server

10%, 1000 Watts Maximum at Start Up. 500 Watts

PREFACE

x

Analog:

Analog Outputs: Qty. 3 Isolated 4-20 mA dc, 500 ohms Max Load (O2, CO, CO2, SO2, or NOx)
*Optional: Additional Qty. 3 (Extended I/O option)
Analog Inputs: Qty 2 (Typically; MW, Fuel Flow)
*Optional: Additional Qty. 2 (Extended I/O option)

Digital
Outputs:
Following are connected directly to the MicroCEM Probe/Sample Handling Box:

Sample Pump on/off, Drain Pump on/off, Purge on/off, Calibrate on/off – All are rated 110VAC @ 1amp Dry Contact.

Qty. 6 dry contact digital Outputs
*Optional Time Share option – Dry Contact used for Stream Indicator.

Digital Inputs:
Qty. 3: (Typical Process on/off, Flame Detect, Shutdown or Initiate Cal)

*Optional three additional Inputs (Extended I/O)

Instrument Weight: 62 lbs Typical
Size: 24“ X 20“ X 12“ (H W D)
Ranges:
O2: 0 –2 Selectable to 0 –25% (1% increments)

CO: 0 –100ppm Selectable to 1000ppm (1ppm increments)
NOx: 0 – 10ppm Selectable to 1000ppm (1ppm increments)

Sample Temperature: 0 degrees C to 55 degrees C
Sample flow rate: .5 to 1.5 liters/min
Warm Up Time: Max 60 minutes @ low ambient temperatures

Linearity
Zero Drift

Span Drift
Repeatability
Response Time (t90)

Influence of Ambient
Temperature
(-20C to 45C)

-On Zero

-On Span

Paramagnetic

O

2

Electro

Chemical O2

<+/- 1% < +/- 1% < +/- 1% < +/- 1%

< +/- 1% /day < +/- 1% /day < +/- 1% /day < +/- 1% /day
< +/- 1% /day < +/- 1% /day < +/- 1% /day < +/- 1% /day

< +/- 1% < +/- 1% < +/- 1% < +/- 1%/day

10< +/-t90< +/-15 10< +/-t90< +/-15 15s< +/-t90< +/-30s 15s< +/-t90< +/-30s

< +/-1%
< +/-1%

< +/-1%
< +/-1%

NDIR

CO

< +/-2%
< +/-2%

Chemiluminescent NO

(1)

(1)

(1)

(1)

< +/-2%
< +/-2%

(1)

0-10ppm NOx range is <+/- 3%.

INTRODUCTION

Specifications – Probe/Sample Handling Enclosure: GENERAL

See separate SHS manual for more details

Power: Universal Power Supply 85 – 125 VAC, 50 – 60 Hz, + 10%
750 Watts Maximum at Start Up. 500 Watts Nominal

Mounting: Customer Flange Mount (2 Hole Top) or Wall Mount for High Temp Option
Area Classification: General Purpose / NEMA 4X Fiberglass Enclosure or Stainless Steel enclosure.
Compliance's: CSA (Pending)
Ambient Range Temperature: -30
Relative Hum: 5 to 99%
Instrument Weight: 95 lbs Typical
Size: 24“ X 34“ X 12“ (H W D)
Stack Sample Moisture: Up to 25% max
Sample Cooler: Thermo Electric dual pass Chiller. Permeation Tube (-30 degrees C.

Dewpoint. Customer instr ument air required @ 5 L/M, -40 degree C dewpoint

Max. Stack Temperature: Standard 400° F.
Optional: 600° F (available with elongated spool option)

High Temp: 1400° F (Off Stack Option)

Stack Pressure: Typical -5 to 15 inches H
Sample Flow Rate: 500 to 2500cc/min
Response Time: Maximum distance between Analysis Enclosure and Sample Conditioning/Probe

Enclosure is 300'. (Response time is 30 seconds/100' w/¼" tubing)..
Probe Length: 48" length 316 SS Probe with .5 micron sintered filter. Customer to cut

to length in field if necessary. Optional 5’ and 6’ probes.

Mounting Flange: Standard 4“ 150# Raised Face. Shipped Equipped with Gasket
Sample Pump: 316 SS diaphragm type

º

to 50º Celsius

O

2

Instrument Air Requirements: Instrument grade air required. 15 SCFM @ 60 -100 PSIG (30
seconds 2 times per day) Pressure Regulation by Customer

Rosemount Analytical µCEM Continuous Analyzer Transmitter xi

INTRODUCTION

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 Divi si on

Customer Service Center

1-800-433-6076

RETURNING PARTS T O TH E 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 P ur chase Order Number or Sale s 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.

1201 North Main St.

Orrville, OH 44667

USA

TRAINING

A comprehensive Facto ry Training Program of operator and service classes is av ailable. For a copy o f
the Current Operator and Service Training Schedule contact the Technical Services Department at:

Rosemount Analytical Inc.

Phone: [phone]

COMPLIANCES

This product may carry approval s from sev eral certifyin g agen cies. The c ertification marks appear on
the product name-rating plat e .

NOTES

INTRODUCTION

1. Introduction

1.1 Overview

This manual describes the Rosemount Analytical Micro Continuous Emission Monitoring (µCEM)
gas Analyzer Module.

The µCEM Analyzer Module is designed to continuously determine the concentration of O2, CO,
CO2, SO2, and NOx in a flo wing gaseo us mixt ure. The co nc entra tion is exp ressed in p ercent o r par ts­per-million.

The sampled gas is collected from the stack and prepared by the Probe/Sample Handling Enclosure for
analysis and processing by the Analy sis Enclosure. The ANALYSIS ENCLOSURE is a s tand alone,
computer-controlled unit, utilizing PC/104 as the system bus. The uCEM is enclosed in rugged NEMA
4X, IP65 type enclosures, fo r harsh environment . The ANALYSIS ENC LOSURE utilizes con vection
cooling with no air intake an d air vents. The ANAL YSIS ENCLOSURE is modular, general purpose
and easily expandable. It utilizes industry standard components such as PC/104 boards, and modular
signal conditioning modules.

Figure 1-1. µCEM Micro Co n t inuous Emission Monitoring – Analysis Enclos u re

Rosemount Analytical µCEM Continuous Analyzer Transmitter 1–1

INTRODUCTION

Figure 1-2. µCEM Micro Continuous Emission Monitoring Gas Analyzer with Time Share
option.

INTRODUCTION

1.2 Time Shared Option

Provides the functionality to monitor and process sample gases from two streams on a time-share scheme. This
option allows you to connect one uCEM to two Sample Handling units.

TV1

FROM

uCEM CAL

TO uCEM

SAMPLE

TO SHU1

CAL GAS

TO SHU2

CAL GAS

FROM SHU1

SAMPLE

FROM SHU2

SAMPLE
EXHAUST

Figure 1-3. Time Share option Flow Diagram

TV2

TV3

TV4

INTRODUCTION

1.3 Theory of Operation

1.3.1 NOx

The NOx analyzer continuously analyzes a flowing gas sample for NOx [nitric oxide (NO) plus nitrogen
dioxide (NO
The µCEM NOx Analyzer Module uses the chemiluminecence method of detection. This technology is based
on NO’s reaction with ozone (O
in an electronically excite d state (NO
with emission of photons (essentially, red light). The reactions involved are:

The sample is continuously passed through a heated bed of vitreous carbon, in which NO
Any NO initially present in the sample passes through the converter unchanged, and any NO
approximately equivalent (95%) amount of NO.
The NO is quantitatively converted to NO
analyzer from air supplied by an extern al source. During the reaction, approximately 10% of the NO
are elevated to an electronically excited state, followed by immediate decay to the non-excited state,
accompanied by emission of photons. These photons are detected by a photomultiplier tube which produces an
output proportional to the concentration of NOx in the sample.
To minimize system response time, an internal sample bypass feature provides high-velocity sample flow
through the analyzer.

1.3.2 CO

The optical bench can selectively measure multiple components in a compact design by using a uniqu e dual
optical bench design. Depending on the application, any two combinations of NDIR channels can be combined
on a single chopper motor/dual source assembly.

Other application-dependent options include a wide r ange of sample cell materials, optical filters and solid state
detectors. The NDIR Microflow detector consists of two chambers, measurement and reference with an
interconnected path in which an ultra low flow filament senso r is mounted. During operation, a pulsating flow
occurs between the two chambers which is dependent upon: sample gas absorption, modulation by the chopper
motor and the fill gas of the detector chambers. The gas flow/sensor output is proportional to the measured gas
concentration. The optical bench is further enhanced by a novel “Look-through” detector technique. This
design allows two detectors to be arranged in series --- enabling two different co mponents to be measured on a
single optical bench. The optical bench contains a unique eddy current drive chopper motor and source
assembly. This design incorporates on board “intelligence” to provide continuous “self test” diagnostics.

)]. The sum of the concentrations is continuously reported as NOx.

2

) to produce NO2 and oxygen (O2). Some of the NO2 molecules produced are

3

* where the * refers to t he excitation). These revert t o the ground state,

2

+ O3 → NO2* + O2

NO

2

* → NO2 + red light

NO

2

by gas-phase oxidation with molecular ozone produced within the

2

is reduced to NO.

2

is converted to an

2

molecules

2

1.3.3 O2

Paramagnetic: The determination of oxygen is based on the measurement of the magnetic susceptibility of the
sample gas. Oxygen is strongly paramagnetic, while other common gases are not. The detector used is
compact, has fast response and a wide dynamic range. The long life cell is corrosion resistant, heated and may
be easily cleaned. It has rugged self-tensioning suspension and is of welded Non-Glued construction.

INTRODUCTION

1.3.4 SO2

The optical bench can selectively measure multiple components in a compact design by using a uniqu e dual
optical bench design. Depending on the application, any two combinations of NDIR channels can be combined
on a single chopper motor/dual source assembly.

Other application-dependent options include a wide range of sample cell materials, optical filters an d solid state
detectors. The NDIR Microflow detector consists of two chambers, measurement and reference with an
interconnected path in which an ultra low flow filament sensor is mounted during operation. A pulsating flow
occurs between the two chambers which is dependent upon: sample gas absorp tion, modulation by the chopper
motor and the fill gas of the detector chambers. The gas flow/sensor output is proportional to the measured gas
concentration. The optical bench is further enhanced by a novel “Look-through” detector technique. This design
allows two detectors to be arranged in series --- enabling two different co mponents to be measured on a single
optical bench. The optical bench contains a unique eddy curren t drive chopper motor and source assembly. This
design incorporates on board “intelligence” to provide continuous “self test” diagnostics.

Detector Methodologies

2. Detector Methodologies

The µCEM can employ up to three different measuring methods depending on the configuration chosen. The
methods are: NDIR CO/CO2/SO2, Paramagnetic O

2.1 Non-Dispersive Infrared (NDIR)

The non-dispersive infrared method is based on the principle of absorption of infrared radiation by the sample
gas being measured. The gas-specific wavelengths of the absorption bands characterize the type of gas while
the strength of the absorption gives a measure of the concentration of the gas component being measured.
An optical bench is employed comprising an infrared light source, two analysis cells (reference and
measurement), a chopper wheel to alt ern a te th e ra diat ion i nten sit y between the referenc e an d measurement side,
and a photometer detector. The detector signal thus alternates between concentration dependent and
concentration independent values. The difference between the two is a reliable measur e of the concentration of
the absorbing gas component.
Depending on the gas being measured and its concentration, one of two different measuring methods may be
used as follows:

2.1.1 Interference Filter Correlation Method

With the IFC method the analysis cell is alternately illuminated with filtered infrared concentrated in one of two
spectrally separated wavelength ranges. One of these two wavelength bands is chosen to coincide with an
absorption band of the sample gas and the other is chosen such that none of the gas constituents expected to be
encountered in practice absorbs anywhere within the band.
The spectral transmittance curves of the interference filters used in the µCEM analyzer and the spectral
absorption of the gases CO and CO
these gases each coincide with the passbands of one of the interference filters. The fourth interference fi lter,
used for generating a reference signal, has its passband in a spectral region where non e of these gases absorb.
Most of the other gases of interest also do not absorb within the passband of this reference filter.
The signal generation is accomplished with a pyroelectrical (solid-state) detector. The detector records the
incoming infrared radiation. This radiation is reduced by the absorption of the gas at the corresponding
wavelengths. By comparing the measurement and reference wavelength, an alternating voltage signal is
produced. This signal results from the cooling and heating of th e pyroelectric detector material.

are shown in Figure 2.1 below. It can be seen that the absorption bands of

2

, Electrochemical O2, and chemiluminescent NOx.

2

Rosemount Analytical µCEM Continuous Analyzer Transmitter 2–1

DETECTOR METHODOLOGIES

Figure 2-1. Absorption Bands of Sample Gas and Transmittance of Interference Filters

2.1.2 Opto-Pneumatic Method

In the opto-pneumatic method, a thermal radiator generates the infrared radiation which passes through the
chopper wheel. This radiation alternately passes through the filter cell and reaches the measuring and reference
side of the analysis cell with equal intensity. After passing another filter cell, the radiation reaches the
pneumatic detector.
The pneumatic detector compares and evaluates the radiation from the measuring and reference sides of the
analysis cell and converts them into voltage signals proportional to their respective intensity.
The pneumatic detector consists of a gas-filled absorption chamber and a compensation chamber which are
connected by a flow channel in which a Microflow filament sensor is mounted. This is shown in Figure 2-2
below.
In principle the detector is filled with the infrared active gas to be measured and is only sensitive to this distinct
gas with its characteristic absorption spectrum. The absorption chamber is sealed with a window which is
transparent for infrared radiation. The window is usually Calcium Fluoride (CaF
When the infrared radiation passes through the reference side o f the analysis cell into the detector, no pre­absorption occurs. Thus, the gas inside the absorption chamber is heated, expands and so me of it passes thro ugh
the flow channel into the compensation chamber.

).

2

DETECTOR METHODOLOGIES

Absorption chamber

Flow channel with
Microflow sensor

CaF

Window

2

Compensation chamber

Figure 2-2. Opto-Pneumatic Gas Detector

When the infrared radiation passes thro ugh the open measurement side of the analysis cell into the detector, a
part of it is absorbed depending on the gas concentration. The gas in the absorption chamber is, therefore,
heated less than in the case of radiati on coming from the reference side. Absorption chamber gas becomes
cooler, gas pressure in the ab sorption chamber is reduced and so me gas fro m the co mpensation cha mber passes
through the flow channel into the absorption chamber.
The flow channel geometry is designed in such a way that it hard ly impedes the gas flow by restri ction. Due to
the rotation of the chopper wheel, the different radiation intensities lead to periodically repeated flow pulses
within the detector.
The Microflow sensor evaluates thes e flow pulse s and converts t hem into electrical pu lses which are p rocessed
into the corresponding analyzer output.

DETECTOR METHODOLOGIES

(

)

2.1.3 Overall NDIR Method

In the case of dual-channel analyzers, the broadband emission from two infrared sources pass through the
chopper wheel. In the case of the Interference Filter Correlation (IFC) method, the infrared radiation then
passes through combinations of interference filters. In the case of the opto-pneumatic method, the infrared
radiation passes through an optical filter depending on the application and need for reduction of influences.
Then the infrared radiation enters the analysis cells from which it is focused by filter cells onto the
corresponding detector. The preamplifier detector output signal is then converted into the analytical results
expressed directly in the appropriat e physical concentration units such as percent volume, ppm, mg/Nm
This is shown in

Figure

2-3 below.

3

, etc.

Figure 2-3. Overall NDIR Method

Pyroelectric detector

solid-state detector

DETECTOR METHODOLOGIES

2.2 Paramagnetic Oxygen Method

The paramagnetic principle refers to the induction of a weak magnetic field, parallel and proportional to the
intensity of a stronger magnetizing field.
The paramagnetic method of determination of oxygen concentration utilizes nitrogen filled quartz spheres
arranged at opposite ends of a bar, the center of which is suspended by and free to rotate on a thin platinum wire
ribbon in a cell. Nitrogen (N2) is used because it is diamagnetic or repelled by a magnet.
A small mirror that reflects a light beam coming from a light source to a photodetector, is mounted on the
platinum ribbon. A strong permanent magnet specifically shaped t o produce a strong, highly inhomogeneous
magnetic field inside the analysis cell, is mounted outside the wall of the cell.
When oxygen molecules enter the cell, their paramagnetism will cause them to be drawn towards the region of
greatest magnetic field strength. The oxygen molecules thus exert different forces on the two suspended
nitrogen filled quartz spheres, producing a torque which causes the mirror to rotate away from its equilibrium
position.
The rotated mirror deflects the incident light onto the photodetector creating an electrical signal which is
amplified and fed back to a coil attached to the bar holding the quartz spheres, forcing the suspend ed spheres
back to the equilibrium position.
The current required to generate the re storing torque to return the quartz bar to its equilibrium position is a
direct measure of the O
The complete paramagnetic analysis cell consists of an analysis chamber, permanent magnet, processing
electronics, and a temperature sensor. The temperatu re sensor is used to control a heat exchanger to warm the
measuring gas to about 55 °C.

concentration in the sample gas.

2

DETECTOR METHODOLOGIES

2.3 Electrochemical Oxygen Method

The electrochemical method of determining oxygen concentration is based on the galvanic cell pr inciple shown
in

Figure 2-4 below.

Figure 2-4. Electrochemical Oxygen Sensor

The electrochemical oxygen sensor incorpo rates a lead and gold galvanic process with a lead anode (1) and a
gold cathode (2), using an acid electrolyte (3).
Oxygen molecules diffuse through a non-porous Teflon membrane (4) into the electrochemical cell and are
reduced at the gold cathode. Water is the byproduct of this reaction.
On the anode, lead oxide is formed which is transferred into the electrol yte. The lead anode is continuously
regenerated and, therefore, the electrode potential remains unchanged for a long time. The rate of diffusion and
corresponding response time (t
The electric current between the electrodes is proportional to the O
measured. The resultant signal is measured as a voltage across the resistor (6) and thermistor (5), the latt er of
which is used for temperature compensation. A change in the output voltage (mV) represents oxygen
concentration.
NOTE: The electrochemical O
oxygen concentration of less than 2% could result in a reversible detuning of sensiti vity and the output will
become unstable. The recommended practice is to purge the cell with conditioned ambient air between periods
of measurement. If the oxygen concentration is below 2% for several hours or days, the cell must be
regenerated for about one day with ambient air. Temporary flushing with nitrogen (N
(analyzer zeroing) will have no effect on the sensitivity or stability.

) of the sensor is dependent on the thickness of the Teflon membrane.

90

cell requires a minimum internal consumption of oxygen. Sample gases with an

2

concentration in the sample gas being

2

) for less than one hour

2

Figure 2-5 Reaction of Galvanic Cell

DETECTOR METHODOLOGIES

INSTALLATION

3. Installation

WARNING: ELECTRICAL SHOCK HAZARD

Installation and servicing of this device requires access to components which may
present electrical shock and/or mechanical hazards. Refer installation and servicing to
qualified service personnel.

CAUTION: CODE COMPLIANCE

Installation of this device must be made in accordance with all applicable national
and/or local codes. See specific references on installation drawing located in the rear of this
manual.

3.1 Specifications

Electrical Power

See Specifications in Preface

Power Cable

AC Operation: 16 gauge, minimum.

Gas Lines

For external gas lines, the use of all new tubing throughout is strongly recommended. The preferred type is
new, Teflon or Stainless Steel tubing, sealed at the ends.

Services

AC as well as input and output digital and analog signals connect through the circular connectors located on the
bottom of the uCEM enclosures.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–1

INSTALLATION

Figure 3-1. Dimensional Drawing, Door closed. Shown with Time Share option with standard Fiberglass

Enclosure.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–2

INSTALLATION

41.49

3.0010.28

14.00

Ø

.440

.62

25.24

32.53

18.00

Figure 3-2. Dimens ional Drawin g, Door closed. Shown with Time Share option with Optional Stainless

Steel Enclosure.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–3

SAMPLE INLET

1/2" NPT

FEMALE CONNECTION

INSTALLATION

STACK

CEMS SHS

ENCLOSURE

(24H X 24W X 12D)

SAMPLE FLOW

INSTRUMENT AIR

(BY CUSTOMER)

ATMOS PRESSURE

DRAIN TO SAFE

LOCATION

FRONT VIEW

LEFT SIDE VIEW

Figure 3-3. Basic Installation Guidel in e

INITIATE AUTO CALIBRATIO N

(3 WIRE CABLE BY CUSTOMER)

SAMPLE FROM
S/C ENCLOSURE

CALIBRATION LINE

TO S/C ENCLOSURE

POWER IN

115 VAC, 60 HZ

5 AMPS

(BY CUSTOMER)

DRY CONTACT

1/4" O.D.
TEFLON TUBING
(BY CUSTOMER)

MID RANGE

TUBING/PRESSURE REGULATOR

STATIONS/CALIB GASES

O2/NO

HIGH RANGE

(BY CUSTOMER)

ANTENNA

PHONE

NITROGENO2/NO

uCEM ANALYZER

RS485

LAN

ENCLOSURE

(24H X 20W X 12D)

ELECTRICAL INPUT/OUTPUT
CONNECTORS

POWER IN, 115 VAC,
60 HZ, XX AMPS
(BY CUSTOMER)

ANALOG OUTPUT

DIGITAL OUTPUT

RS232

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–4

INSTALLATION

O2 IN

{

INST

ATMOS

AIR

PRES

BY

DRAIN

CUST

TO SAFE
PLACE

O2 IN

{

INST

ATMOS

AIR

PRES

BY

DRAIN

CUST

TO SAFE
PLACE

ELECTRICAL
CONNECTIONS

ELECTRICAL
CONNECTIONS

Figure 3-4. Basic Installation Guideline – Time Share Option

CAL GAS
IN (CUST)

CAL GAS

O2 IN

OUT

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–5

INSTALLATION

Figure 3-5. Standard System Flow Diagram

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–6