Rosemount™ 1500XA
Process Gas Chromatograph
Reference Manual
2-3-9000-762, Rev C
May 2022
Notice
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Warranty
LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise expressly provided
1.
herein, Emerson (“Seller”) warrants that the firmware will execute the programming instructions provided by Seller and
that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under
normal use and care until the expiration of the applicable warranty period. Goods are warranted for twelve (12) months
from the date of initial installation or eighteen (18) months from the date of shipment by Seller, whichever period expires
first. Consumables and Services are warranted for a period of 90 days from the date of shipment or completion of the
Services. Products purchased by Seller from a third party for resale to Buyer (“Resale Products”) shall carry only the
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making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If Buyer
discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty period, Seller shall, at
its option, promptly correct any errors that are found by Seller in the firmware or Services, or repair or replace F.O.B. point
of manufacture that portion of the Goods or firmware found by Seller to be defective, or refund the purchase price of the
defective portion of the Goods/Services. All replacements or repairs necessitated by inadequate maintenance, normal
wear and usage, unsuitable power sources, unsuitable environmental conditions, accident, misuse, improper installation,
modification, repair, storage or handling, or any other cause not the fault of Seller are not covered by this limited
warranty, and shall be at Buyer's expense. Seller shall not be obligated to pay any costs or charges incurred by Buyer or any
other party except as may be agreed upon in writing in advance by an authorized Seller representative. All costs of
dismantling, reinstallation and freight, and the time and expenses of Seller's personnel for site travel and diagnosis under
this warranty clause shall be borne by Buyer unless accepted in writing by Seller. Goods repaired and parts replaced during
the warranty period shall be in warranty for the remainder of the original warranty period or ninety (90) days, whichever is
longer. This limited warranty is the only warranty made by Seller and can be amended only in a writing signed by an
authorized representative of Seller. Except as otherwise expressly provided in the Agreement, THERE ARE NO
REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR
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that corrosion or erosion of materials is not covered by our guarantee.
LIMITATION OF REMEDY AND LIABILITY: SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN
2.
PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY HEREUNDER SHALL BE LIMITED TO
REPAIR, CORRECTION, REPLACEMENT, OR REFUND OF PURCHASE PRICE UNDER THE LIMITED WARRANTY CLAUSE IN
SECTION 1 HEREIN. IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER BASED IN
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DAMAGES. THE TERM “CONSEQUENTIAL DAMAGES” SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF ANTICIPATED
PROFITS, LOSS OF USE, LOSS OF REVENUE, AND COST OF CAPITAL.
Certifications and safety information
Your installation must comply with all certifications and safety instructions.
Rosemount 1500XA Gas Chromatograph system
Rosemount 1500XA Gas Chromatographs are designed to meet the specifications for Class 1, Division 2, Groups B, C, and D area
classification using a Z-purge system. An optional Nationally Recognized Testing Laboratory (NRTL) third party certification is
2
available when ordering. This option ensures that an NRTL organization has reviewed, tested, and certified the Rosemount
1500XA Gas Chromatograph to the applicable product safety test standards.
NOTICE
The Rosemount 1500XA is field certified product by an National Recognized Testing Lab for both US and Canadian standards.
Internal components or related assemblies may contain their own individual product certifications.
Rosemount 1500XA Gas Chromatograph system optional certification
Class 1, Division 2, Groups B, C, and D
Rosemount 1500XA Gas Chromatograph intrinsically safe back plane
Class I, Division 2 Groups B, C, and D
Associated equipment for: Class I, Division 1, Groups B, C, and D
Ex nA [ic IIB + H2 Gc] IIB + H2 Gc
Zone 2 AEx nA [ic IIB + H2 Gc] IIB+ H2 Gc
Rosemount 1500XAGas Chromatograph explosion-proof flame ionization detector (FID)
Class I, Division 1 Groups B, C, and D
Ex db IIB+H2 Gb
Class I, Zone 1, AEx db IIB+H2 Gb
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Reference Manual Contents
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Contents
Chapter 1 About Rosemount 1500XA Gas Chromatographs........................................................7
1.1 Overview..................................................................................................................................... 7
1.2 Software description..................................................................................................................10
1.3 Embedded gas chromatograph (GC) firmware...........................................................................10
1.4 Rosemount MON2020...............................................................................................................10
1.5 Equipment description.............................................................................................................. 12
Chapter 2 Getting started.........................................................................................................19
2.1 Site selection............................................................................................................................. 19
2.2 Unpack the gas chromatograph (GC).........................................................................................19
2.3 Necessary tools and components.............................................................................................. 20
2.4 Optional tools and components.................................................................................................21
Chapter 3 Installation and start-up .......................................................................................... 23
3.1 Install a gas chromatograph (GC) in hazardous environments....................................................23
3.2 Gas chromatograph wiring........................................................................................................ 24
3.3 Installing the analyzer................................................................................................................ 27
3.4 Leak checking and purging for first calibration...........................................................................68
3.5 Start up the system....................................................................................................................71
3.6 Start a 2-point calibration.......................................................................................................... 72
Chapter 4 Maintaining and troubleshooting the gas chromatograph........................................75
4.1 Maintenance and repairs in hazardous environments................................................................ 75
4.2 Troubleshooting and repair....................................................................................................... 75
4.3 Routine maintenance................................................................................................................ 76
4.4 Access to gas chromatograph (GC) components....................................................................... 78
4.5 Precautions for handling printed circuit (PC) assemblies............................................................ 78
4.6 Troubleshooting........................................................................................................................ 79
4.7 Checking the GC for leaks.......................................................................................................... 99
4.8 Repairing and maintaining the valves.........................................................................................99
4.9 Repairing and maintaining the detectors................................................................................. 102
4.10 Replacing the methanator..................................................................................................... 109
4.11 Measure vent flow................................................................................................................. 110
4.12 Access electrical components................................................................................................111
4.13 Analog inputs and outputs.....................................................................................................113
4.14 Upgrading the embedded software....................................................................................... 113
Appendix A Theory of operation................................................................................................115
A.1 Thermal conductivity detector (TCD)...................................................................................... 115
A.2 Flame ionization detector (FID)............................................................................................... 117
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A.3 Data acquisition...................................................................................................................... 117
A.4 Peak detection........................................................................................................................ 118
A.5 Basic analysis computations.................................................................................................... 119
A.6 Functional description............................................................................................................. 121
Appendix B Specifications......................................................................................................... 125
Appendix C Local operator interface (LOI)................................................................................. 127
C.1 Local operator interface (LOI) for displaying and entering data................................................ 127
C.2 Local operator interface (LOI).................................................................................................. 128
C.3 Using the local operator interface (LOI)................................................................................... 129
C.4 Navigate and interact with the screen......................................................................................140
C.5 Local operator interface (LOI) screens......................................................................................148
C.6 Troubleshoot a blank local operator interface (LOI) display screen...........................................178
Appendix D Carrier gas installation and maintenance................................................................179
D.1 Carrier gas...............................................................................................................................179
D.2 Install manifold and purge line................................................................................................ 180
D.3 Replace carrier cylinder........................................................................................................... 181
Appendix E Recommended spare parts.....................................................................................183
Appendix F Shipping and long-term storage recommendations................................................185
Appendix G Pre-defined Modbus® map files..............................................................................187
Appendix H Engineering drawings............................................................................................ 189
H.1 List of engineering drawings....................................................................................................189
Appendix I Glossary................................................................................................................. 191
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1 About Rosemount 1500XA Gas
Chromatographs
1.1 Overview
The Rosemount 1500XA is a high-speed gas chromatograph (GC) that is factory
engineered to meet specific field application requirements based on stream composition
and the anticipated concentration of the components of interest.
This GC was fully inspected and tested before it left the factory. Program parameters were
installed and documented in the GC Config Report furnished with the USB stick shipped in
your documentation package.
Components
The GC typically consists of two major components, the analyzer assembly and the sample
conditioning system (SCS).
Analyzer assembly (XA series)
The assembly includes:
□ Columns
□ Detectors
□ Preamplifier
□ Valves
□ Solenoids
□ Analyzer, which includes:
— Electronics and ports for signal processing
— Pressure control
— Instrument control
— Data storage
— Personal computer (PC) interface
— Telecommunications
Sample conditioning system
The SCS is located between the process stream and the analyzer sample inlet, usually
mounted on the lower portion of the analyzer stand.
Optionally, we can configure the SCS with Genie® bypass filters, liquid shut-off valves, and
optional solenoids for stream switching, all of which can be enclosed in an electric (heat
tape design) oven.
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The standard configuration SCS includes:
• Mounting plate
• Block (or shutoff) valves
• Filters
In its standard configuration, the analyzer can handle multiple streams.
Operation
Although the GC can be operated from the local operator interface (LOI), it is designed to
be run primarily from PC running Rosemount MON2020 software. The PC provides you
with the greatest capability, ease of use, and configuration flexibility. One PC running
Rosemount MON2020 can connect with multiple gas chromatographs over a local area
network. The GC’s Ethernet capability makes it possible to interact with the GC even if it is
located in a hazardous area. You can use a PC to display chromatograms and reports,
which can then be stored as files on the PC’s hard drive.
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Typical installation
Figure 1-1: System overview
A. ¼-in. connector carrier in
B. ¼-in. connector valve actuation gas
C. Electronics enclosure
D. Air-bath oven
E. ¼-in. air regulator in
F. ¾-in. customer connection
G. LOI display
H. ¼-in. air regulator
I. Z-Purge pressure regulator
J. ¾-in. customer connection
K. ¾-in. customer connection
L. Mechanical pressure regulator panel
M. Cyclops Z-Purge indicator
Documentation
This Manual provides information on operating the GC.
For software operation instructions, see the Rosemount MON2020 Software for Gas
Chromatographs Reference Manual (PN 2-3-9000-745). The reference and software
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manuals are included on the Rosemount MON2020 software USB stick that ships with the
GC. Alternatively, you can download them from Emerson.com.
Related information
Local operator interface (LOI)
Rosemount MON2020
1.2 Software description
The gas chromatograph (GC) uses two distinct types of software. This enables total
flexibility in defining the calculation sequence, report content, format, type and amount of
data for viewing, control, and/or transmission to another computer or controller
assembly.
The two types are:
• Embedded GC firmware
• Rosemount MON2020 software
The application configuration is tailored to the customer’s process and shipped on a USB
stick. The hardware and software are tested together as a unit before the equipment
leaves the factory.
Rosemount MON2020 communicates with the GC and can be used to initiate site system
setup, such as operational parameters, application modifications, and maintenance.
1.3 Embedded gas chromatograph (GC) firmware
The GC’s embedded firmware supervises operation of the Rosemount 1500XA through its
internal microprocessor-based controller.
All direct hardware interface is via this control software. It consists of a multitasking
program that controls separate tasks in system operation, as well as hardware self-testing,
user application downloading, start-up, and communication. After configuration, the GC
can operate as a stand-alone unit.
1.4 Rosemount MON2020
Emerson has designed the Rosemount 1500XA Gas Chromatograph (GC) to operate
unattended. If adjustments are needed, Emerson's proprietary desktop software,
Rosemount MON2020, allows complete control of the GC either locally or remotely.
From the software, you can:
• Start or stop analysis, calibration, or validation cycles.
• Configure, ignite, and check the status of the flame photometric detector (FPD) or the
flame ionization detector (FID) flames.
• Generate and save current and historical analysis and calibration reports.
• Review and modify analytical settings.
• Upload and display multiple chromatograms for comparison.
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• Upload and trend any of the measured results.
• Export data to text, HTML, or Microsoft® Excel™ for use in third party applications.
• Check on original calibration against the last calibration.
• Perform GC operation checks and modifications simultaneously.
• Upload and view manuals and drawings stored in the gas chromatograph.
Rosemount MON2020 is a Windows®-based software program that makes analyzer
configuration, maintenance, and data collection easy. With intuitive drop-down menus
and fill-in-the-blank tables, even new users can quickly navigate through the software.
Figure 1-2: Rosemount MON2020 interface
A. Simple drop-down menus
B. Connect to any GC with a mouse click
C. Full featured chromatogram display
D. Response Factor fidelity chart
E. Fully detailed Timed Events table
F. Automatic listing of measured components
G. Quickly add chromatograms to overlay
H. Save chromatograms to hard drive
With its abilities to communicate with your enterprise network and export to numerous
file types, Rosemount MON2020 is a powerful tool that ensures operators, engineers,
maintenance personnel, and management have access to critical data, such as current and
archived chromatograms, alarm history, event logs, and maintenance logs.
The software's chromatogram viewer allows you to view and compare both live and
archived chromatograms simultaneously. Despite its small size, the chromatogram file
includes analysis and calculation results, integration and valve time settings, retention
time settings, and raw peak data.
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The trend viewer makes it easy to trend multiple variables on a single chart. To help
diagnose process or analysis issues, you can select single or multiple points on the trend
viewer; the chromatograms associated with these points will open in the chromatogram
viewer. You can save the trend files or export them as text, CSV, or Excel files.
Rosemount MON2020 can connect to a Rosemount GC via Ethernet directly or over your
local or wide area network. The software is equipped with multi-level username and
password security settings to limit and control access to the GC and provide levels of
access authority ranging from read-only access to full control of the GC and its data.
1.5 Equipment description
The Rosemount 1500XA Gas Chromatograph combines the proven analytical components
of the Rosemount 700XA Gas Chromatograph with the larger oven capacity and flexibility
of a traditional air-bath oven design.
1.5.1
Electronics enclosure
The Rosemount 1500XA electronics enclosure contains:
• Card cage assembly
• Local operator interface (LOI)
• Backplane
• AC/DC power supply
• Circuit breaker
• Solenoid valves
• Electronic pressure controllers (EPCs)
• Z-purge controller
Local operator interface (LOI)
The LOI gives you in-depth control over the functions of the gas chromatograph (GC).
The LOI has a high resolution color display that is touch key activated and allows you to
operate the GC without a computer.
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Figure 1-3: LOI
The LOI includes the following features:
• Color LCD display with VGA (640 x 480 pixels) resolution
• ASCII text and graphics modes
• Adjustable auto-backlighting
• Eight infrared-activated touch screen keys that eliminate the requirement for a
magnetic pen
• Complete GC status, control, and diagnostics, including full chromatogram display
Pressure switch
The pressure switch activates when the carrier pressure falls below a predetermined set
point. When activated, the switch triggers a general alarm that displays on the local
operator interface (LOI) and in Rosemount MON2020.
Mechanical pressure regulators
The mechanical pressure regulators and gauges are used to set and monitor the pressure
of the carrier gas flow through the gas chromatograph's columns, as well as the pressure
of the flame ionization detector (FID) or flame photometric detector (FPD) air and fuel
(H2), if installed.
The regulators and gauges are typically located on the top or side of the electronics
enclosure.
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Figure 1-4: Regulators and Gauges
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Electronic pressure controller (EPC) interface board
The XA EPC interface board is an electronic circuit board designed to control EPCs.
Figure 1-5: EPC board
A. EPC boards
B. LEDs
C. J21: Power connector
D. F1: 5 amp fuse
E. Switch 1: Controller area network (CAN) communication
F. J2: JTAG
G. J1: USB debug port
H. Switch 2: Not applicable (only used for gas chromatographs with multiple EPC boards)
The EPC board comes with an on-board microprocessor which allows it to communicate to
other processors over a controller area network (CAN). You can use the JTAG interface to
load firmware onto the board. The EPC board also includes a mini USB interface, which can
be used for debugging internal board operations.
The EPC board is powered at 24 Volts through a four pin connector (J21), which also
contains the CAN differential lines that allow for communication to the gas
chromatograph's (GC's) main central processing unit (CPU) board. A 5 amp fuse ensures
power cut-off in case of an electrical malfunction. There are also over-voltage and undervoltage cut-off circuits to ensure that the board can only operate between 18 and 30
Volts.
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Switch 1 enables the termination for CAN communication. Set both switches on the switch
1 device to ON. Always set switch 2 on the EPC board to 0. Switch 2 is designed to allow for
multiple EPC boards to use the CAN interface. Since there is only one EPC board in a
Rosemount 1500XA, always keep this switch set to 0.
The EPC board contains connections for up to 12 EPCs (J11 to J19), which the operator can
control simultaneously to regulate pressure and give feedback on EPC device details. Each
EPC channel is designed to power the EPC device at 24 V and communicate with it over a
standard RS-232 serial interface. There are 12 LEDs placed under the EPC connectors,
which show the communication state of each connected EPC. Upon start-up, the EPC
board attempts to communicate with each channel. If the board finds an EPC on the
channel, the corresponding green LED lights up, showing that the communication
attempt was successful. If an EPC is present, but the board can't communicate with it, the
corresponding red LED lights up. If there is no EPC connected to the channel, the EPC LED
will not light up.
1.5.2
Air-bath oven
The air-bath oven uses a conventional instrument air heater design for maximum
analytical flexibility.
The oven has capacity for up to eight chromatograph valves and four detectors. It also has
the capacity for liquid sample injector valves (LSIVs) for heavier samples.
The oven can operate at temperatures up to 248 °F (120 °C) as the application dictates.
The air-bath oven contains the valves, the columns, the detectors, and the stream
switching system.
Note
The analyzer can have a maximum of two flame detectors (flame ionization detector and
flame photometric detector) and/or four thermal conductivity detectors (TCDs). The oven
cannot contain two flame photometric detectors (FPDs), but it can contain two flame
ionization detectors (FIDs).
A more detailed component list for the oven compartment includes the following:
Table 1-1: Air-bath oven components
Component Description
Valves Up to 8 XA pneumatically actuated valves.
Column module Columns are either capillary or micro-packed.
TCDs Supports a maximum of 4 TCDs.
Temperature switch Switch for the heating element. The switch turns off its heating
element if the heating element reaches 257 °F (160 °C).
FID The optional FID can be used in place of a TCD to detect trace
levels of compounds.
Micro flame photometric detector (µFPD) The optional µFPD uses a photo multiplier tube (PMT) to collect
the light emitted when the sample is burned in the presence of
air and hydrogen. The sample of gas to be measured is also
injected into the burner.
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Table 1-1: Air-bath oven components (continued)
Component Description
LSIV The optional LSIV converts a liquid sample into a gas sample for
gas chromatograph (GC) analysis.
Oven heater
1.5.3 Sample system
A well designed, properly adjusted sampling system is essential for optimum performance
of any gas chromatograph (GC). If a good sample is not obtained for analysis, the system is
compromised.
The purpose of the sample handling system is to transfer a conditioned fluid sample that is
compatible with gas chromatography requirements.
The sample conditioning system (SCS) is located between the process stream and the
analyzer, and is usually mounted beneath the air-bath oven. It serves these purposes:
• Extracts final sample from the fast loop.
• Performs final filtration.
• Performs stream switching for a multi-stream analyzer.
• Adjusts the final pressure, temperature, and flow on the selected sample flowing to the
sample valve.
When selecting and installing a sampling system, consider the following:
• Sample point
• Sample volume and flow rate
• Sample conditioning
• Contamination precautions
• Valving
• Calibration gas
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2 Getting started
2.1 Site selection
The site selected for the gas chromatograph (GC) is important for measurement accuracy.
Install the GC as close as possible to the sample system but allow for adequate access
space for maintenance tasks and adjustments. Allow a minimum of 3 ft. (0.9 m) in front of
the GC for operator access.
Ensure that exposure to radio frequency (RF) interference is minimal.
WARNING
HAZARDOUS AREA EXPLOSION HAZARD
Failure to follow this warning may result in injury or death to personnel.
Do not use a personal computer (PC) or printer in a hazardous area. Serial and Ethernet
communication links are provided to connect the analyzer to the PC and to other
computers and printers in a safe area.
WARNING
VENTILATION
If you plan to place the GC in a sealed shelter, always vent the GC to atmosphere with ¼-in.
tubing or larger. This will prevent the build-up of gases.
2.2 Unpack the gas chromatograph (GC)
Unpack and inspect the Rosemount 1500XA upon receipt.
Procedure
1. Unpack the equipment.
a) Remove the GC from the shipping crate.
b) Remove the USB memory stick containing the software, applications, Quick
Start Guide, and manuals.
Note
The Rosemount MON2020 version number is located on the back of the USB
card.
2. Retain the shipping information.
3. Inspect all parts and assemblies for possible shipping damage.
4. If any parts or assemblies appear to have been damaged in shipment, first file a
claim with the carrier.
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5. Next, complete a full report describing the nature and extent of the damage and
forward this report immediately to your Emerson Customer Care representative.
Include the GC's model number in the report.
Emerson will provide disposition instructions as soon as possible. If you have any
questions regarding the claim process, contact your Emerson Customer Care
representative for assistance.
6. Only proceed to install and start up the GC if all required materials are on hand and
free from obvious defects.
2.3 Necessary tools and components
You will need the following tools and components to install the analyzer.
• Chromatographic grade carrier gas: 99.995% pure with less than 5 ppm water and 0.5
ppm hydrocarbons. Possible carriers gases (application dependent) include:
— Helium
— Nitrogen
— Argon
— Hydrogen
• High pressure dual-stage regulator for the carrier gas cylinder: high side up to
3,000 psig (206.84 barg); low side capable of controlling pressure up to 150 psig
(10.34 barg).
• Calibration standard gas with correct number of components and concentrations.
• Dual-stage regulator for the calibration gas cylinder, low pressure side capable of
controlling pressure up to 30 psig (2.07 barg).
• Sample probe (fixture for procuring the stream, or sample gas for chromatographic
analysis).
• Stainless steel tubing:
— ⅛ in. for connecting calibration standard to analyzer.
— ⅛ in. for connecting stream gas to the analyzer.
— ¼ in. for connecting carrier to the analyzer.
• Sulfur-inert coated , stainless steel tubing for H2S applications.
• Miscellaneous Swagelok® tube fittings, tubing benders and tubing cutter.
• 14 AWG (18 MWG) or larger electrical wiring and conduit to provide
115 or 220 volts AC, single phase, 50 to 60 Hertz (Hz), from an appropriate circuit
breaker and power disconnect switch.
• Digital volt-ohm meter with probe-type leads.
• A flow measuring device.
• Phillips antistatic screwdriver.
• 7/32-in. Allen wrench.
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• Channel lock wrench
Related information
Wiring precautions
2.4 Optional tools and components
WARNING
EXPLOSION HAZARD
Electrostatic discharges may cause an explosion. Serial port and Ethernet are provided to
connect the gas chromatograph (GC) to the personal computer (PC) and to connect to
other computers and printers in a safe area. Failure to follow this warning may result in
injury or death to personnel.
Do not use a PC in a hazardous area.
Supporting tools and components include:
• A Windows™-based PC and either a direct or remote communications connection to
interface with the Rosemount 1500XA. See the Rosemount MON2020 Software for Gas
Chromatographs Reference Manual for more information on specific PC requirements.
• The Rosemount 1500XA has a factory-wired Ethernet port on the back plane.
• Modbus® communications are optional
Related information
Connect directly to a personal computer (PC) using the gas chromatograph's (GC’s)
Ethernet1 port
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3 Installation and start-up
Note
Because the Rosemount 1500XA is available in different configurations, it is possible that
not all of the instructions in this section apply to your particular gas chromatograph (GC).
In most cases, however, to install and set up a Rosemount 1500XA, Emerson recommends
that you follow the instructions in the same order as they are presented in this manual.
3.1 Install a gas chromatograph (GC) in hazardous environments
WARNING
Follow these precautions if installing or operating the GC in a hazardous area.
Procedure
1. Do not operate a personal computer (PC) in a hazardous area. To interface with a
GC in a hazardous area, use a PC that is remotely connected to the GC and that is
located in a nonhazardous area.
2. Ensure that field connections to the analyzer and the GC are appropriately certified
and made through purged conduit or flameproof glands.
WARNING
Failure to observe all regulations when installing purged GC units may result in
noncompliance, equipment damage, or personal injury.
Observe all applicable regulations when installing purged GC units.
The purged analyzer housing is designed for use in locations where fire and
explosion hazards may exist, specifically areas that are classified by the National Fire
Protection Association (NFPA) as Class I, Division 2, Group B, C, and D. However,
other regulations do apply. Consult the authority having jurisdiction or appropriate
site policies and procedures regarding wiring and installation practices.
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3.2 Gas chromatograph wiring
3.2.1 Wiring precautions
• All wiring, as well as circuit breaker or power disconnect switch locations, must
conform to the CEC or NEC; all local, state, or other jurisdictions; and company
standards and practices.
• Provide single-phase, three-wire power at 115 or 220 Vac, 50-60 Hz.
NOTICE
If you do not have a single phase, three-wire AC power source, you must purchase an
isolation transformer.
• Locate a power shut-off or disconnect switch in a safe area.
• Provide the gas chromatograph (GC) and any optionally installed devices with one 20-
amp circuit breaker for protection.
3.2.2
NOTICE
15 amps is the maximum current for 14 American Wire Gauge (AWG).
• Use multi-stranded copper conductor wire according to the following
recommendations:
— For power feed distances up to 250 ft (76 m), use 14 AWG (18 metric wire gauge
[MWG]), stranded.
— For power feed distances 250 ft (76 m) to 500 ft (152 m), use 12 AWG (25 MWG),
stranded.
— For power feed distances 500 ft (152 m) to 1,000 ft (305 m), use 10 AWG (30
MWG), stranded.
Signal wiring
Follow these general precautions for field wiring digital and analog input/output (I/O)
lines:
• For shielded signal conducting cables, shield-drain wires must not be more than two
American Wire Gauge (AWG) sizes smaller than the conductors for the cable. Shielding
is grounded at only one end.
• Metal conduit or cable (according to local code) used for process signal wiring must be
grounded at conduit support points, because intermittent grounding helps prevent the
induction of magnetic loops between the conduit and cable shielding.
• A single-point ground must be connected to a copper-clad, 10 ft (3.05 m) long, 0.75 in
(19.0 mm) diameter steel rod, which is buried, full-length, vertically into the soil as
close to the equipment as is practical.
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NOTICE
The grounding rod is not furnished.
• Resistance between the copper-clad steel ground rod and the earth ground must not
exceed 25 Ohms.
• On ATEX-certified units, the external ground lug must be connected to the customer’s
protective ground system via 9 AWG (6 mm2) ground wire. After the connection is
made, apply a non-acidic grease to the surface of the external ground lug to prevent
corrosion.
• The equipment-grounding conductors used between the gas chromatograph (GC) and
the copper-clad steel ground rod must be sized according to your local regulations; the
following specifications apply in the US.
• All interior enclosure equipment-grounding conductors must be protected by metal
conduit.
• External equipment that is connected to the GC should be powered via isolation
transformers to minimize the ground loops caused by the internally shared safety and
chassis grounds.
• All process signal wiring should be of a single, continuous length between field devices
and the GC. If, however, the length of the conduit runs require that multiple wiring
pulls be made, the individual conductors must be interconnected with suitable
terminal blocks.
• Use suitable lubrication for wire pulls in conduit to prevent wire stress.
• Use separate conduits for AC voltage and DC voltage circuits.
• Do not place digital or analog I/O lines in the same conduit as AC power circuits.
• Use only shielded cable for digital I/O line connections.
— Ground the shield at only one end.
— Shield-drain wires must not be more than two American Wire Gauge (AWG) sizes
smaller than the conductors for the cable.
• When inductive loads (relay coils) are driven by digital output lines, the inductive
transients must be diode-clamped directly at the coil.
• Any auxiliary equipment wired to the GC must have its signal common isolated from
earth/chassis ground.
NOTICE
Signal interference
If you don't follow this precaution, the data and control signals to and from the GC could
be adversely affected.
Do not place any loop of extra cable left for service purposes inside the GC purged housing
near the conduit entry for AC power.
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3.2.3 Electrical conduit installation precautions
• Conduit cutoffs must be cut at a 90-degree angle. Cut conduits with a cold cutting tool,
hacksaw, or by some other approved means that does not deform the conduit ends or
leave sharp edges.
• Coat all conduit fitting-threads, including factory-cut threads, with a metal-bearing
conducting grease prior to assembly.
• Temporarily cap the ends of all conduit runs immediately after installation to prevent
accumulation of water, dirt, or other contaminants. If necessary, swab out conduits
prior to installing the conductors.
• Install drain fittings at the lowest point in the conduit run; install seals at the point of
entry to the gas chromatograph (GC) to prevent vapor passage and accumulation of
moisture.
• Use liquid-tight conduit fittings for conduits exposed to moisture.
When a conduit is installed in hazardous areas, follow these general precautions for
conduit installation:
• All conduit runs must have a fitting, which contains explosion-proof sealing (potting)
located within 3 in (76 mm) from the conduit entrance to the explosion-proof housing.
The seal should have a minimum IP rating of IP54 or equivalent NEMA®/Type rating on
the conduit sealing devices.
• The conduit installation must be vapor tight, with threaded hub fittings, sealed conduit
joints and gaskets on covers, or other approved vapor-tight conduit fittings.
WARNING
Failure to observe precautionary signs may result in serious injury or death to personnel.
Observe all precautionary signs posted on the certified explosion-proof equipment.
Consult your company's polices and procedures and other applicable documents to
determine wiring and installation practices that are appropriate for hazardous areas.
3.2.4 Sample system requirements
Line length If possible, avoid long sample lines. In long flow sample lines, velocity
can be increased by decreasing downstream pressure and using
bypass flow via a fast loop.
NOTICE
Stream switching requires a sample pressure of 20 psig (1.38 barg).
Sample line tubing material • Use sulfur-inert tubing for H2S streams; for all other applications,
use stainless steel tubing.
• Ensure tubing is clean and free of grease.
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Dryers and filters Use small sizes to minimize time lag and prevent back diffusion.
• Install a minimum of one filter to remove solid particles. Most
applications require fine-element filters upstream of the gas
chromatograph (GC). The GC includes a 2-micron filter.
• Use ceramic or porous metallic type filters. Do not use cork or felt
filters.
NOTICE
Install the probe/regulator first, immediately followed by the
coalescing filter and then the membrane filter.
Pressure regulators and
flow controllers
Pipe threads and dressings Use PTFE tape. Do not use pipe thread compounds or pipe dope.
Valving • Install a block valve downstream of sample takeoff point for
Related information
Carrier gas installation and maintenance
• Use stainless steel wetted materials.
• Parts should be rated for sample pressure and temperature.
maintenance and shutdown.
• The block valve should be a needle valve or cock valve type, of
proper material and packing, and rated for process line pressure.
3.3 Installing the analyzer
WARNING
EXPLOSION HAZARD
Failure to de-energize the analyzer may cause an explosion and severely injure personnel.
Do not open the enclosure unless the area is known to be non-hazardous or unless all
devices within the enclosure have been de-energized.
Do not restore power after opening the enclosure until it has been purged for 60
minutes at a pressure of 0.3 in. w.c.
3.3.1 Connect power to the gas chromatograph (GC)
WARNING
ELECTRIC SHOCK
Failure to observe all safety precautions could result in serious injury or death.
Do not connect AC power leads without first ensuring that the AC power source is
switched off.
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Figure 3-1: Circuit Breaker
A. Electronics enclosure
B. Circuit breaker
Procedure
1. Locate the three leads for connecting power to the GC.
The leads are colored as follows:
GC power wiring
Hot Black
Neutral White
Ground Green
Color
2. Connect the leads to the AC power source (i.e., with circuit breaker and power
disconnect switch).
Make power line splices and conduit seals that comply with applicable electrical
code and hazardous area wiring requirements.
WARNING
ELECTRIC SHOCK
Failure to properly connect the GC unit may result in serious personal injury.
Do not apply power to the GC until all power, interconnection, and external signal
connections have been verified and proper grounds have been made.
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3. If necessary, connect the analyzer's chassis ground to an external copper ground
rod (at remote locations).
4. Close the electronics enclosure door and apply power to the GC.
3.3.2 Connect gas lines
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Procedure
1. Remove the plug from the 1/16-in sample vent tubing marked SV1 that is located
on the flow panel assembly.
Figure 3-2: Sample vent and measure vent lines
A. Sample and gas line vents
• If desired, connect the sample vent lines to an external, ambient pressure vent. If
the vent line is terminated in an area exposed to wind, protect the exposed vent
with a metal shield.
• Use ¼-in or ⅜-in tubing for vent lines longer than 10 ft (3.05 m).
NOTICE
Do not discard the vent line plugs. They are useful when leak-checking the gas
chromatograph (GC) and its sample or gas line connections.
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