Rosemount MicroCEM TS Analysis Enclosure-Rev 2.1 Manuals & Guides

Download

ntt

all

yttii

all

Mii

crr

Annaallyyssiiss EEnncclloossuurree

Micro Continuous Emission Monitor

Operation & Maintenance Manual

Revision 2.1, Oct. 13, 03

Part Number 1021021-100

Rosemount Analytical UCEM Continuous Analyzer Transmitter

CONTENTS

Safety Summary ………………………………………………………………………… ………… … 1 Specifications – Analysis Enclosure: General …………………………………………………….. 4 Specifications – Probe/Sample Handling Enclosure: General ..………………………………… 5 Customer Service, Technical Assistance and Field Service ………..………………………….. 6 Returning Parts to the Factory………………………………………………………………………. 6 Training ……………………………………………………………………………… ………………... 7

Preface

Intended Use Statement …………………………………………………………………………….. 1

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

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

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

1.3 Theory of Operation.........................................................................................................1–5

1.3.1 NOx..................................................................................................................................1–5

1.3.2 CO ...................................................................................................................................1–5

1.3.3 O2....................................................................................................................................1–6

1.3.4 SO2..................................................................................................................................1–7

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........................................................................3–5

3.2.1 Gas Conditioning.............................................................................................................3–6

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

3.3.1 Location...........................................................................................................................3–1

3.3.2 Limitations........................................................................................................................3–1

3.3.3 Mounting Options.............................................................................................................3–1

3.3.4 Electrical Connections.....................................................................................................3–1

3.3.4.1 Circular Connector Assembly Instructions.......................................................................3–2

3.3.4.2 EXT I/O Interface Connector ...........................................................................................3–4

3.3.4.3 SHU #1 / #2 Interface Connector.....................................................................................3–6

3.3.4.4 COM Interface Connector................................................................................................3–1

3.3.4.5 Lan Interface Connector..................................................................................................3–1

3.3.4.6 CPU I/O Interface Connector...........................................................................................3–1

3.3.4.7 SSU Power Connector, T/S units Only............................................................................3–2

3.3.4.8 AC Power Connector.......................................................................................................3–2

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

3.3.5.1 Flow Indicator Method .....................................................................................................3–1

3.3.5.2 Manometer Method..........................................................................................................3–1

3.3.5.3 Troubleshooting Leaks ....................................................................................................3–3

4. Startup and Operation........................................................ 4–1

4.1 Startup Procedure............................................................................................................4–1

4.2 Analyzer Operation.......................................................................................................... 4-1

4.2.1 User Interface...................................................................................................................4-1

4.2.2 µCEM Main Window.........................................................................................................4-2

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

4.2.4 µCEM Alarms................................................................................................................... 4-6

Rosemount Analytical µCEM Continuous Analyzer Transmitter 2

CONTENTS

4.2.5

4.2.6 µCEM Login-Current User Indication................................................................................4-9

4.2.7 Stream Switching Control...............................................................................................4-10

4.3 µCEM Settings............................................................................................................... 4-11

4.3.1 µCEM Settings-Range....................................................................................................4-11

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 ..................................................................................................4-165

4.3.5 µCEM Settings-Calibration Gas....................................................................................4-186

4.3.6 µCEM Settings-Maintenance Mode 4- 18

4.3.7 µCEM Settings-Manual Calibration.............................................................................4-1918

4.3.8 µCEM Settings-Auto Calibration Dialog .....................................................................4-1519

4.4 µCEM Administration....................................................................................................... 4-2

4.4.1 µCEM Administration-User Settings.................................................................................4-2

4.4.2 µCEM Administration-Auto Logoff ....................................................................................4-3

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

4.6 uCEM Data Logs ............................................................................................................. 4-7

4.6.1 Maximum Log File Size ....................................................................................................4-7

4.6.2 Maximum Number of Log Files.........................................................................................4-7

4.6.3 Log File Name Format......................................................................................................4-7

4.6.4 Measurement Log File Format..........................................................................................4-8

4.6.5 Calibration Log File Format ..............................................................................................4-8

4.6.6 Alarm Log File Format....................................................................................................4-10

4.6.7 Accessing the Real-Time ACSII Data String via Ethernet TCP/IP (DAS).....................4-101

4.7 Viewing µCEM Data and Diagnotics with the Pocket PC Web Browser..........................4-1

4.8 Viewing µCEM Data with a Web Browser........................................................................ 4-1

4.8.1 Real-Time Page................................................................................................................ 4-1

4.8.2 Emissions Page................................................................................................................4-3

4.8.3 Download Page ................................................................................................................4-6

4.9 Viewing µCEM Data with MS Excel................................................................................. 4-7

4.10 Auto Calibration............................................................................................................... 4-1

CEM Login......................................................................................................................4-8

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

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

5.2 Converter......................................................................................................................... 5-3

5.3 Ozonator.......................................................................................................................... 5-3

5.4 Personality Modules ........................................................................................................ 5-3

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

5.6 Central Processing Unit................................................................................................... 5-8

5.6.1.1 Features........................................................................................................................... 5-8

5.6.1.2 EMBEDDED ENHANCED BIOS:..................................................................................... 5-9

5.6.2 Analog/Digital I/O Board...................................................................................................5-9

5.6.2.1 Automatic Calibration..................................................................................................... 5-10

5.6.2.2 Analog Inputs................................................................................................................. 5-10

5.6.2.3 Programmable Input Ranges......................................................................................... 5-11

5.6.2.4 Enhanced Trigger and Sampling Control Signals.......................................................... 5-11

5.6.2.5 Analog Outputs.............................................................................................................. 5-11

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

5.6.2.7 Specifications................................................................................................................. 5-12

5.6.3 PCMCIA Adapter............................................................................................................5-13

5.6.3.1 Features......................................................................................................................... 5-14

5.6.3.2 SOFTWARE FEATURES:.............................................................................................5-14

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

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3

CONTENTS

5.6.4.1 Features......................................................................................................................... 5-15

5.6.5 Flash Drive........................................................................................................................5-1

5.6.5.1 Specifications................................................................................................................... 5-1

5.6.6 Pocket PC.........................................................................................................................5-1

5.6.7 Wireless LAN Adapter ......................................................................................................5-2

5.6.8 500 Watts Power Supply ..................................................................................................5-3

5.6.8.1 FEATURES...................................................................................................................... 5-3

5.7 Replacement Parts.......................................................................................................... 5-4

5.7.1 Replacement Part list........................................................................................................5-4

5.8 System Enclosure............................................................................................................ 5-9

5.9 Trouble LED................................................................................................................... 5-10

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

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4

PREFACE

NTENDED 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 IMPORTANT BUT NOT HAZARD RELATED

IS USED TO INDICATE INSTALLATION, OPERATION, OR MAINTENANCE INFORMATION WHICH

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

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).

Rosemount Analytical µCEM Continuous Analyzer Transmitter 1

PREFACE

DANGER: TOXIC GAS

This device may contain explosive, toxic or unhealthy gas components. Before cleaning or changing parts in the gas paths, purge the gas lines with ambient air or nitrogen.

WARNING: ELECTRICAL SHOCK HAZARD

POSSIBLE EXPLOSION HAZARD

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

WARNING: ELECTRICAL SHOCK 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

Avoid inhalation of the exhaust gases at the exhaust fitting.

of consciousness, and death.

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.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 2

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

SE TWO PERSONS OR A SUITABLE LIFTING DEVICE TO MOVE OR

CARRY THE INSTRUMENT

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3

SPECIFICATIONS - GENERAL

SPECIFICATIONS – Analysis Enclosure: GENERA L

Power: Universal Power Supply 85 – 125 VAC, 50 – 60 Hz, + 10%, 1000 Watts

Maximum at Start Up. 500 Watts Nominal

MicroProcessor: Intel Celeron processor, 566MHz, 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), UV (SO2), Paramagnetic (O2), Electrochemical (O2),

Chemiluminscent (NOx) // Up to three in one analyzer

Mounting: Wall Mount Area Classification: General Purpose / NEMA 4X Fiberglass Enclosure Compliant Compliance's: CSA (Pending) Ambient Temperature Range: -30

to 500 Celsius.

PREFACE

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

Analog:

Analog Outputs: Qty. 3 Isolated 4-20 mA dc, 500 ohms Max Load (O2, CO or SO2, 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)

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4

PREFACE

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 digital Outputs - TTL: 5 VDC Max Current 20 mA *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)

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5

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 25 minutes @ low ambient temperatures

PREFACE

Linearity Zero Drift

Span Drift Repeatability Response Time (t90)

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

-On Zero

-On Span

(1)

Paramagnetic

)

Electro

Chemical O

<+/- 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

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

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

NDIR

15s< +/-t

< +/-

30s

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

Chemiluminescent

NOx

(1)

15s< +/-t

< +/-30s

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

Rosemount Analytical µCEM Continuous Analyzer Transmitter 6

PREFACE

SPECIFICATIONS – Probe/Sample Handling Enclosure: GENERAL

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 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 instrument air required @ 5 L/M, -40 degree C dewpoint

Max. Stack Temperature: Standard 400 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/1/4" 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 Instrument Air Requirements: Instrument grade air required. 15 SCFM @ 60 -100 PSIG (30

seconds 2 times per day) Pressure Regulation by Customer

to 500 Celsius

CUSTOM ER SERVICE, TECHNICAL ASSIST ANCE AND FIELD SER VICE

For order administration, replacement parts, application assistance, on-site or factory repair, service or maintenance contract information, contact:

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

RETURNING PARTS TO THE FACTORY

Before returning parts, contact the Customer Service Center and request a Returned Materials Authorization (RMA) number. Please have the following information when you

Rosemount Analytical µCEM Continuous Analyzer Transmitter 1

call: Model Number, Serial Number, and Purchase Order Number or Sales Order

Number.

Prior authorization by the factory must be obtained before returned materials will be accepted. Unauthorized returns will be returned to the sender, freight collect.

When returning any product or component that has been exposed to a toxic, corrosive or other hazardous material or used in such a hazardous environment, the user must attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification that the material has been decontaminated, disinfected and/or detoxified.

Return to:

Rosemount Analytical Inc.

1201 North Main St.

Orrville, OH 44667

USA

PREFACE

TRAINING

A comprehensive Factory Training Program of operator and service classes is available. For a copy of the Current Operator and Service Training Schedule contact the Technical Services Department at:

Rosemount Analytical Inc.

Phone: 1-330-682-9010

COMPLIANCES

This product may carry approvals from several certifying agencies. The certification marks appear on the product name-rating plate.

NOTES

Rosemount Analytical µCEM Continuous Analyzer Transmitter 2

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, SO2, and NOx in a flowing gaseous mixture. The concentration is expressed in percent or parts-per-million.

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

Rosemount Analytical µCEM Continuous Analyzer Transmitter 1–1

INTRODUCTION

Figure 1-1. µCEM Micro Continuous Emission Monitoring – Analysis Enclosure

Rosemount Analytical µCEM Continuous Analyzer Transmitter 1–2

INTRODUCTION

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

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.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 1–3

TV1

INTRODUCTION

FROM

uCEM CAL

TO uCEM

SAMPLE

TO SHU1

CAL GAS

TO SHU2

CAL GAS

FROM SHU1

SAMPLE

FROM SHU2

SAMPLE EXHAUST

TV2

TV3

TV4

Figure 1-3. Time Share option Flow Diagram

Rosemount Analytical µCEM Continuous Analyzer Transmitter 1–4

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 reported as NOx.

The µCEM NOx Analyzer Module uses the chemiluminecence method of detection. This technology is based on NO’s reaction with ozone (O (O

). Some of the NO2 molecules produced are in an electronically excited state (NO2*

where the * refers to the excitation). These revert to the ground state, with emission of photons (essentially, red light). The reactions involved are:

+ O3 → NO2* + O

NO2* → NO2 + red light

The sample is continuously passed through a heated bed of vitreous carbon, in which NO

is reduced to NO. Any NO initially present in the sample passes through the

converter unchanged, and any NO amount of NO.

)]. The sum of the concentrations is continuously

) to produce NO2 and oxygen

is converted to an approximately equivalent (95%)

1.3.2 CO

The NO is quantitatively converted to NO

by gas-phase oxidation with molecular

ozone produced within the analyzer from air supplied by an external source. During the reaction, approximately 10% of the NO

molecules 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 highvelocity sample flow through the analyzer.

The optical bench can selectively measure multiple components in a compact design by using a unique 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 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 sensor 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 components 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.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 1–5

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

Rosemount Analytical µCEM Continuous Analyzer Transmitter 1–6

1.3.4 SO2

INTRODUCTION

Other application-dependent options include a wide range 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 sensor 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 components 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.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 1–7

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/SO2, Paramagnetic O Electrochemical O

, and chemiluminescent NOx.

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 alternate the radiation intensity between the reference and 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 measure 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 can be seen that the absorption bands of these gases each coincide with the passbands of one of the interference filters. The forth interference filter, used for generating a reference signal, has its passband in a spectral region where none 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 the pyroelectric detector material.

are shown in Figure 2-1 below. It

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 of the analysis cell into the detector, no pre-absorption occurs. Thus, the gas inside the absorption chamber is heated, expands and some of it passes through the flow channel into the compensation chamber.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 2–2

DETECTOR METHODOLOGIES

Absorption chamber

CaF

Window

Flow channel with Microflow sensor

Compensation chamber

Figure 2-2. Opto-Pneumatic Gas Detector

When the infrared radiation passes through 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 radiation coming from the reference side. Absorption chamber gas becomes cooler, gas pressure in the absorption chamber is reduced and some gas from the compensation chamber passes through the flow channel into the absorption chamber.

The flow channel geometry is designed in such a way that it hardly impedes the gas flow by restriction. Due to the radiation of the chopper wheel, the different radiation intensities lead to periodically repeated flow pulses within the detector.

The Microflow sensor evaluates these flow pulses and converts them into electrical pulses which are processed into the corresponding analyzer output.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 2–3

DETECTOR METHODOLOGIES

(hig

)

(

)

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 appropriate physical concentration units such as percent volume, ppm, mg/Nm 2-3 below.

MOTOR

Light source

, etc. This is shown in Figure

Chopper

blade

Analysis cell

measurin

Analysis cell

reference side

Gas detector

side

Filter cell

Duplex filter disc

Adapter cell

h measuring range Analysis cell

undivided)

Filter cell Preamplifier

Pyroelectric detector

solid-state detector

Preamplifier

Chopper

blade

Figure 2-3. Overall NDIR Method

Rosemount Analytical µCEM Continuous Analyzer Transmitter 2–4

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 to 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 suspended spheres back to the equilibrium position.

The current required to generate the restoring torque to return the quartz bar to its equilibrium position is a direct measure of the O

concentration in the sample gas.

The complete paramagnetic analysis cell consists of an analysis chamber, permanent magnet, processing electronics, and a temperature sensor. The temperature sensor is used to control a heat exchanger to warm the measuring gas to about 55 °C.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 2–5

DETECTOR METHODOLOGIES

2.3 Electrochemical Oxygen Method

The electrochemical method of determining oxygen concentration is based on the galvanic cell principle shown in Figure 2-4 below.

Lead wire (Anode) Lead wire (Cathode) Anode (1) (Lead)

O-Ring

Plastic disc (9) Plastic top (10)

Figure 2-4. Electrochemical Oxygen Sensor

(Black)

(Red)

Resistor (6) Thermistor (5) Acid electrolyte (3) Spong3 disc (7) Cathode (2) (Gold film)

Teflon membrane (4)

The electrochemical oxygen sensor incorporates 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 electrolyte. 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

)

of the sensor is dependent on the thickness of the Teflon membrane. The electric current between the electrodes is proportional to the O

concentration in

the sample gas being measured. The resultant signal is measured as a voltage across the resistor (6) and thermistor (5), the latter of which is used for temperature compensation. A change in the output voltage (mV) represents oxygen concentration.

NOTE: The electrochemical O

cell requires a minimum internal consumption of

oxygen. Sample gases with an oxygen concentration of less than 2% could result in a reversible detuning of sensitivity 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

) for less than one hour (analyzer zeroing) will have no effect

on the sensitivity or stability.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 2–6

DETECTOR METHODOLOGIES

(Red) V out (Black)

Thermistor (5) Resistor (6)

(-) (+) Gold Lead Cathode (2) Anode (1)

O2 + 4 H + 4 e → 2 H2O 2 Pb + 2 H2O → 2PbO + 4 H + 4 e Electrolyte (3)

(ph 6)

Summar

reaction O2+ 2 Pb → 2 PbO

Figure 2-5 Reaction of Galvanic Cell

Rosemount Analytical µCEM Continuous Analyzer Transmitter 2–7

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.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–2

INSTALLATION

O2 IN

{

INST

ATMOS

AIR

PRES

DRAIN

CUST

TO SAFE PLACE

O2 IN

ELECTRICAL CONNECTIONS

CAL GAS IN (CUST)

CAL GAS

O2 IN

OUT

{

INST

ATMOS

AIR

PRES

DRAIN

CUST

TO SAFE PLACE

ELECTRICAL CONNECTIONS

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–3

INSTALLATION

4" 150 LB

ASA RF

FLANGE

CONNECTION

SAMPLE FLOW

4" 150 LB

ASA RF

FLANGE

CONNECTION

SAMPLE FLOW

REMOTE

OPERATION

FROM MCEM

14 5

CONTROLLER

SET FOR

8-12 PSIG

RV1

OUT

RC1B

DRAIN

1/4SSBH/

3/8SSR

REMOTE OPERATION FROM MCEM

CONTROLLER

SET FOR

8-12 PSIG

RV1

OUT

RC1B

DRAIN

1/4SSBH/

3/8SSR

SV1

1/2 NPT MALE

SP1

TI1

EC1

SLOPE

SAMPLE CALIB

BLOW BACK

SHU

1/2 NPT MALE

SP1

TI1

EC1

SLOPE

BLOW BACK

A C

SAMPLE

SHU

EOV1

CBA

SLOPE

CALIB

SLOPE

1011

OUT

RC1A

DRAIN

ATMOS PRESSURE

DRAIN TO SAFE

LOCATION

SV1

EOV1

OUT

RC1A

DRAIN

ATMOS PRESSURE

DRAIN TO SAFE

LOCATION

FI1

ADJUST FOR

3-4 L/MIN

FI1

ADJUST FOR

3-4 L/MIN

PI1

PR1

ADJUST FOR

20-30 PSIG

PPD1

610

ATMOS PRESSURE

DRAIN TO SAFE

LOCATION

PI1

PR1

ADJUST FOR

20-30 PSIG

PPD1

ATMOS PRESSURE

DRAIN TO SAFE

LOCATION

1/4SSBH/

3/8SSR

1/4SSBH/

3/8SSR

1/4SSBH/

3/8SSR

1/4SSBH/

3/8SSR

1/4SSBH/

3/8SSR

MS1

1/4SSBH/

3/8SSR

1/4SSBH/

3/8SSR

1/4SSBH/

3/8SSR

MS1

INSTRUMENT AIR

60-125 PSIG

-40°F DEW POINT 1-5 SCFM

CAL GAS

1-2 LITER/MIN

SAMPLE/CAL TO ANALYZER 1-2 LITER/MIN

STREAM 1

INSTRUMENT AIR

60-125 PSIG

-40°F DEW POINT 1-5 SCFM

CAL GAS

1-2 LITER/MIN

SAMPLE/CAL TO ANALYZER 1-2 LITER/MIN

STREAM 2

STACK LOCATION

ANALYZER LOCATION

DE-ENERGIZED=STREAM 1

ENERGIZED=STREAM 2

uCEM SAMPLE

uCEM CAL

SHU 1 CAL GAS

SHU 2 CAL GAS

SHU 1 SAMPLE

SHU 2 SAMPLE

EXHAUST

1/4" O.D. X .035 WALL TUBING (BY CUSTOMER)

1/4" SS BULKHEAD

NO C

SSU

ENCLOSURE

HAMMOND

P/N PJ1086L

X PPM NO

IN NITROGEN

SPAN GAS

8-12 PSIG

SV1

SV2

SV3

+24VDC 3A

PRS2

CYL2

20.9% O2

IN NITROGEN

ZERO GAS

8-12 PSIG

PRS1

CYL1

CAL

SAMPLE

HIGH

LOW

ZERO

1/4 SSBH

MANIFOLD

1/4 SSBH

EXHAUST

PI1

PR1

SET FOR

12 PSIG

BY CUSTOMER

1.0 LPM ±0.5 LPM SV4

CNCNO

SV3

SV2

SV1

OZ AIR

BPR

SET FOR

5 PSIG

SET FOR

OZONE

GENERATOR

uCEM

CONTROL UNIT

PRESSURE

SWITCH

DETECTOR

OPTIONAL

DETECTOR

NOX TO NO

CONVERTER

J6J7

EO2

NDIR

DETECTOR

ASSY

REACTION

CHAMBER SAMPLE OZONE

Y R

EXHAUST

A L L

I P A C

SPU

Figure System Flow Diagram

31270 BULKHEAD PLATE

100-900-472-04

MANIFOLD AND

2W1.3W-5DR-E2.46

2 WAY VALVES

108

CAL

901090

029650

016432

1/4 X 1/8 BRASS

1/4 X 1/4 BULKHEAD

SAMPLE

CAL GAS 1

CAL GAS 2

CAL GAS 3

OZONE AIR

EXHAUST

NOTES:

1. ALL TUBING 31413 1/8 DIA. NATURAL UNLESS OTHERWISE INDICATED.

3W16W-1NR-V2A6

3 WAY VALVE

008436 1/8NPT-1/8t

FLOW

1/8FPT-1/8t

904958

10-32w/seal - 1/8 t (barb)

904958

10-32w/seal - 1/8 t (barb)

904958

10-32w/seal - 1/8 t (barb)

10-32 SET

SCREW

CRES

079112

1/4 TUBING

816533

CYL

029753 "T" CRES

005088

PLUG

658157

RESTRICTOR

BRASS

A12

SV1

SV2

A11

SV3

SV4

10-32 SET

SCREW

904958 10-32w/seal - 1/8 t (barb)

SWAGELOC SS-ORM2 TRIM VALVE

1/8NPT-1/8t

RMA-14SSV

FLOW METER

& VALVE

008436

1/8NPT-1/8t

CRES

905277 1/4t "X"

DWYER

016429

810156 1/8MPT-1/8t"T"

112

812902 REDUCER

816553

1/8FPT-1/8t

904017

REGULATOR

638614 GAUGE

903205

905876

1/8MPT

-1/8t"T"

657719

31415

53-030-06 1/4 VITON TUBING

FRICTION FRICTION

42715604 NDIR DETECTOR

9032-904

128

029753 "T" CRES

A34

31412 1/4 VITON TUBING

90003311 PARAMAGNETIC

DETECTOR 902899 (4)

128

M4 X 16 SCREW

A13

903205

(634398)

1/4 TUBING

31414

OUT

FRICTION I/8 TUBE INSIDE 1/4 TUBE

CABLE

A15

656250

632784

FRICTION

632784 FRICTION

903348

31414

634398

812922

659754 PHOTO DIODE

100

DETECTOR

812922

904956

Figure 3-3 Analysis Enclosure Internal Gas flow diagram

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–4

INSTALLATION

Analysis Enclosure Critical settings and control:

1. Set MicroCEM Pressure guage (P1)to 5 psig +/- 0.5psig. Pressure set by BPR located behind gauge in detector section. If CO and NOx response times are sluggish this pressure can be increased.

2. Set Calibration gas cylinder dual stage pressure regulators to 10 to 20 psig.

3. Set Flowmeter (F1) to 500cc to 1500cc per min.

4. TV1 is used to balance the flow between a probe and local calibration. It is located beside the solenoid valve manifold.

5. Set Ozone air pressure to 12 psig.

6. Exhaust line should be free of any backpressure. Immediately vent into ½” pipe.

7. Time Share Box:

TV1: Use to equalize cal gas flow between SHU1 and SHU2. TV2: Use to equalize cal gas flow between SHU1 and SHU2. TV3: Use to equalize sample flow between SHU1 and SHU2. TV4: Use to equalize sample flow between SHU1 and SHU2.

8. Pressure Switch: The pressure switch is located beside the pressure gauge. If the sample or cal gas pressure flow below 2.5 psig the MicroCEM will give trouble alarm. The alarm will turn off upon pressure above 4 psig.

3.2 Process and Calibration Gas Connection

Besides sample gas, the µCEM requires other gases for operation. In most cases, one or more Calibration Standards must be provided. These should be cylinders of gas which closely resemble the expected sample, both in species and concentrations. These calibration gases are normally introduced into the system as an input to the Sample Conditioning Plate Option or sample conditioning may be provided by others.

Each gas cylinder should be equipped with a clean, hydrocarbon free two-stage regulator with indicating gauges of approximately 0 to 3000 psig (0 to 20.7 Mpa) for cylinder pressure and 0 to 100 psig (0 to 689 Kpa) for delivery pressure. Regulators should have a metallic as opposed to elastomeric diaphragm, and provide for ¼ inch compression fitting outlet and should be LOX clean.

NOTE: All connections specified in the Installation Drawing, in conjunction with the Application Data Sheet, should be made.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–5

INSTALLATION

Figure 3-5. Gas Connections

1 – Sample Gas Inlet (From Probe)

5 – Gas 1 Inlet (Cal Gas) 6 – Ozone/Air Inlet

2 – Calibration Gas (From Probe)

(By Cust)

3 – Gas 3 Inlet (Cal Gas)

7 – Vent (To Cust vent)

4 – Gas 2 Inlet (Cal Gas)

3.2.1 Gas Conditioning

All gases must be supplied to the analyzer as conditioned gases! When the system is used with corrosive gases, it must be verified that there are no gas components which may damage the gas path components.

The gas conditioning must meet the following conditions: Free of condensable constituents

Free of dust above 2 µm Free of aggressive constituents which may damage the gas paths Temperature and pressure in accordance with the specifications

When analyzing vapors, the dewpoint of the sample gas must be at least 10 °C below the ambient temperature in order to avoid the precipitation of condensate in the gas paths.

An optional barometric pressure compensation feature can be supplied for the µCEM. This requires a pressure sensor with a range of 800 – 1,100 hPa. The concentration

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–6

INSTALLATION

values computer by the detectors will then be corrected to eliminate erroneous measurements due to changes in barometric pressure.

The gas flow rate must be in the range of 0.5 l/min to a maximum of 1.5 l/min. A constant flow rate of 1 l/min is recommended. NOTE: The maximum gas flow rate for paramagnetic oxygen detectors is 1.0 l/min!

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–7

INSTALLATION

3.3 Installation

WARNING: ELECTRICAL SHOCK HAZARD

Care should be taken if hazardous gases are to be measured or used for calibration.

Refer to installation drawing supplied with the application data package.

3.3.1 Location

The µCEM is designed to be installed in an outdoor environmental location. It is highly recommended that the analyzer be located out of direct sunlight and direct rain/snow to the extent possible to assure longevity and accuracies.

The µCEM analysis enclosure should be installed as near as possible to the probe/sample handling enclosure, in order to avoid low response time caused by long sample gas lines.

The enclosure must be grounded to earth by the user or ground loops and computer lockups are possible.

3.3.2 Limitations

Ambient Temperature: -30° to 50° Celsius (-34° to 122° F) Relative Humidity: 5% to 99%

3.3.3 Mounting Options

Although the µCEM is enclosed in an environmentally sealed enclosure, it should be protected from direct sunlight. In areas subjected to harsh winter climates, protection should be provided from sun, rain and snow. A corrigated awning or other suitable means can be provided to meet these conditions.

3.3.4 Electrical Connections

NOTE: The enclosure is a NEMA 4x. All entry locations must be sealed.

Connect all required signal cables to the connections at the bottom of the µCEM. The cable locations are indicated on the inside bottom cover of the µCEM box. The actual electrical connections will be specified in the Application Data package. All connections are not necessary for every application.

Cable length for these signals should not exceed 3,000 feet (914 meters), to avoid excessive capacitance and corresponding signal distortion.

All connections are made through the bottom of the µCEM enclosure using circular connectors. Mating circular external connectors are provided by Rosemount with a 6’ wire harness pigtail for connections to J1, J3, J5, J6, J7 & J8.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–1

INSTALLATION

SSU

SHU 2

SHU 1

EXT I/O

LAN

COM

CPU I/O

AC POWER

INPUT

Figure 3-6 Electrical Connections

J1 – AC Power Input J2 – CPU I/O J3 – COM Interface (pocket pc) J4 – Ethernet LAN Port J5 – EXT I/O Interface J6 – SHU #1 Interface J7 – SHU #2 Interface (T/S units only) J8 – SSU Power (T/S units only)

3.3.4.1 Circular Connector Assembly Instructions

Refer to Figure 3-7 for instructions.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–2

INSTALLATION

Figure 3-7. Circular Connector Assembly Instructions

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–3

INSTALLATION

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

The Analog Interface connector has a shell size of 22, 100 contacts. Each pin will accept a wire size of 26, 24, or 22 AWG. Connector and 6’ pigtail by Rosemount.

Pin# NAME DESCRIPTION COLOR AWG NOTES

1 O2CL+ WHT 22 2 O2CL-

O2 Stream#1 Reading, 4-20 mA Output

BLK 22

Analog Output /

Twisted Pair wire

3 COCL+ WHT 22 4 COCL5 NOxCL+ WHT 22 6 NOxCL7 EXP1CL+ WHT 22 8 EXP1CL-

9 EXP2CL+ WHT 22 10 EXP2CL11 FLAME1 WHT 22 12 FLAME1RTN 13 PROCON1 WHT 22 14 PROCON1RTN 15 O2CL2+ WHT 22 16 O2CL217 WHT 22 18 COCL2-

CO Stream#1 Reading, 4-20 mA Output

NOx Stream#1 Reading, 4-20 mA Output

External process (No. 1), Customer Analog input, 4-20 mA

External process (No. 2), Customer analog input, 4-20 mA

Flame Detect OR Initiate calibration, Stream#1, Optically Isolated Input (Dry contact by customer)

Process On, Stream#1, Optically Isolated Input (Dry contact by customer)

O2 Stream#2 Reading, 4-20 mA Output

CO Stream#2 Reading, 4-20 mA Output

BRN 22

RED 22

ORG 22

YEL 22

GRN 22

BLU 22

VIO 22

GRY 22

Analog Output /

Twisted Pair wire

Analog Output /

Twisted Pair wire

nalog Input / Twisted

Digital Input / Twisted

Pair wire (Cust

Digital Input / Twisted

Analog Output /

Twisted Pair wire

Analog Output /

Twisted Pair wire

Pair wire

19 NOxCL2+ BLK 22 20 NOxCL221 EXP3CL+ BLK 22 22 EXP3CL23 EXP4CL+ BLK 22 24 EXP4CL25 FLAME2 BLK 22 26 FLAME2RTN 27 PROCON2 BLK 22 28 PROCON2RTN 29 TRBLNO BLK 22 30 TRBLC BLU 22 31 TRBLNC

NOx Stream#2 Reading, 4-20 mA Output

External process (No. 3), Current Loop input, 4-20 mA

External process (No. 4), Current Loop input, 4-20 mA

Flame Detect, Stream#2, Optically Isolated Input (Wet contact)

Process On, Stream#2, Optically Isolated Input (Wet contact)

Trouble Indicator, Dry contact, 110V 1A Rating

BRN 22

RED 22

ORG 22

YEL 22

GRN 22

BLK 22

Analog Output /

Twisted Pair wire

nalog Input / Twisted

Pair wire

nalog Input / Twisted

Pair wire

Digital Input / Twisted

Pair wire

Digital Input / Twisted

Pair wire

Digital Output /

Twisted Pair wire

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–4

INSTALLATION

94 Spare 32 Shutdown1+ BLK 22 33 Shutdown134 O2LR+ BRN 22 35 O2LR36 COLR+ BRN 22 37 COLR38 NOxLR+ BRN 22 39 NOxLR40 O2OL+ BRN 22 41 O2OL42 COOL+ BRN 22 43 COOL44 NOxOL+ BRN 22 45 NOxOL-

ShutDown, Stream#1 Mode (Wet contact)

O2 Range indicator (0V =range 1, 5V = range 2 )

CO Range indicator (0V =range 1, 5V = range 2 )

NOx Range indicator (0V =range 1, 5V = range 2 )

O2 Over Limit Indicator OR Valid (0V = normal, 5V = alarm )

CO Over Limit Indicator OR In Calibration (0V = normal, 5V = alarm )

NOx Over Limit Indicator OR In Maintenance (0V = normal, 5V = alarm )

VIO 22

GRY 22

RED 22

ORG 22

YEL 22

GRN 22

BLU 22

VIO 22

Digital Input / Twisted

Digital Output TTL /

Pair wire

Twisted Pair wire

46 STNNO BRN 22 47 STNC 74 BAROP+ RED 22

75 BAROP98 Spare RED 22

100 Spare

72 Shutdown2+ RED 22 73 Shutdown2-

Stream Number Indicator, Optically Isolated Output, Drty contact (open = Stream#1 / closed = Stream#2)

ShutDown, Stream#2 Mode (Wet contact)

GRY 22

YEL 22

ORG 22

Digital Input / Twisted

GRN 22

Table 3-1. EXT I/O Terminal Assignments

Digital Output /

Twisted Pair wire

Not Used

Spare

Pair wire

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–5

INSTALLATION

3.3.4.3 SHU #1 / #2 Interface Connector (J6 & J7). These wires are to be connected directly to the MicroCEM sample handling enclosure (SHU) and will control the operation of the sample pump, drain pump, purge valve and calibration valve respetively. All toggle

switches in sample handling enclosure should be set to “remote” mode upon hookup of wire so the MicroCEM analysis enclosure will control the full system.

The Digital Interface connector has a shell size of 14, 15 contacts. Each pin will accept a wire size of 20 AWG. Connector and 6’ pigtail by Rosemount.

PIN NAME DESCRIPTION COLOR Sample Handling

1 SPUMP1/2NO BLK Not Used 2 SPUMP1/2C BRN 1 3 SPUMP1/2NC 4 DPUMP1/2NO ORG Not Used 5 DPUMP1/2C YEL 1 6 DPUMP1/2NC

Sample Pump #1/2 Control,

Dry contact, 110V 1A

RED 8

Drain Pump #1/2 Control,

Dry contact, 110V 1A

GRN 3

Enc. Termination

7 PURG1/2NO BLU 4 8 PURG1/2C VIO 1

9 PURG1/2NC 10 CAL1/2NO WHT 5 11 CAL1/2C WHT/BLK 1 12 CAL1/2NC

Purge Valve #1/2 Control,

Dry contact, 110V 1A

GRY Not Used

Calibration Valve #1/2

Control, Dry contact,

110V 1A

WHT/BRN Not Used

Internal Jumper terminals 2 and 9 set by Rosemount

Table 3-2. Sample Handling Unit Terminal Assignments

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–6

INSTALLATION

3.3.4.4 COM Interface Connector (J3) – Pocket PC external connection

The COM Interface connector has a shell size of 10, 13 contacts. Each pin will accept a wire size of 28, 26, or 24 AWG. Connector and 3’ pigtail by Rosemount.

SIGNAL NAME DEFINITION PIN

DCD (pin 1) DSR (pin 6)

RxD (pin 2) RTS (pin 7)

TxD (pin 3) CTS (pin 8) DTR (pin 4)

RI (pin 9)

GND (pin 5) Signal Ground, RS232 9

TxD/RxD+ (pin 2)

TxD/RxD- (pin 7)

GND (pin 3)

VCC

Data Carrier Detect Input, RS232 Data Set Ready Input, RS232 Receive Data Input, RS232 Request to Send Output, RS232 Transmit Data Output, RS232 Clear To Send Input, RS232 Data Terminal Ready Output, RS232 Ring Indicator Input, RS232

RS-485 Bidirectional Data RS-485 Bidirectional Data Signal Ground +5V DC

Table 3-3. COM Interface Terminal Assignments

1 2 3 4 5 6 7 8

10 11 12 13

3.3.4.5 Lan Interface Connector (J4) – Customer PC, network or laptop connection

The Lan Interface connector has a shell size of 8, 6 contacts. Each pin will accept a wire size of 28, 26, 24, or 22 AWG.

SIGNAL NAME DEFINITION PIN

TxD+ (pin 1) 1

TxD- (pin 2)

RxD+ (pin 3) 3

RxD- (Pin 6)

Transmit Data

Receive Data Not Used

Table 3-4. LAN Interface Terminal Assignments

5-6

3.3.4.6 CPU I/O Interface Connector (J2) – Rosemount Factory trained port for communication with CPU hard drive

The CPU I/O Interface connector has a shell size of 14, 19 contacts. Each pin will accept a wire size of 28, 26, or 24 AWG.

PIN NAME DESCRIPTION

A RED RED CENTER

B GND RED SHIELD C GREEN GREEN CENTER D GND GREEN SHIELD E BLUE BLUE CENTER F GND BLUE SHIELD

G HSYNC GREY CENTER

H GND GREY SHIELD

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–1

J VSYNC BLACK CENTER K GND BLACK SHIELD

L DATA DCC DATA

M CLK DCC CLK

N KBDATA KEYBOARD DATA P KBCLK KEYBOARD CLOCK R GND GROUND S VCC VCC, +5VDC R GND GROUND S VCC VCC, +5VDC T MSDATA MOUSE DATA U MSCLK MOUSE CLOCK

Table 3-5. CPU I/O Terminal Assignments

INSTALLATION

3.3.4.7 SSU Power Connector, T/S units Only (J8) – T/S enclosure can be located away from the Analysis enclosure. This cable serves as the connection and is by Rosemount.

The SSU Power connector has a shell size of 8, 3 contacts. Each pin will accept a wire size of 24, 22, or 20 AWG. Connector and 6’ pigtail by Rosemount.

SIGNAL NAME DEFINITION PIN

SSUCtrl Vbb_rtn

Gnd

SSU Control line +24V Return GND

A B

Table 3-6. SSU Power Connection Terminal Assignments

3.3.4.8 AC Power Connector (J1) – Customer 120VAC Power Connection

The AC Power Interface connector has a shell size of 12, 3 contacts. Each pin will accept a wire size of 16 AWG. Connector and 6’ pigtail by Rosemount.

SIGNAL NAME DEFINITION PIN

L1 A L2

GND AC Ground B

85-264 VAC, 47-440 Hz

Table 3-7. AC Power Connection Terminal Assignments

Connect AC power through a 20A circuit breaker that is to be located close to the µCEM. The circuit breaker will provide over current protection as well as a means of disconnecting the power.

Maximum power requirements will be 1000 watts, with most applications requiring less than this amount

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–2

INSTALLATION

Figure 3-4. uCEM Analysis Enclosure interconnect diagram

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–3

INSTALLATION

3.3.5 Analytical Leak Check

If explosive or hazardous gas samples are being measured with the µCEM, it is recommended that gas line fittings and components be thoroughly leak-checked prior to initial application of electrical power, and at bimonthly intervals thereafter, as well as after any maintenance which involves breaking the integrity of the sample containment system.

3.3.5.1 Flow Indicator Method

Figure 3-8. Leak Test Flow Method Supply air or inert gas such as nitrogen, at 10 psig (689 hPa), to the analyzer through a

flow indicator with a range of 0 to 250 cc/min. Install a shut-off valve at the sample gas

outlet. Set the flow rate to 125 cc/min.

Close the outlet shut-off valve and notice that the flow reading drops to zero. If the flow reading does not drop to zero, the system is leaking and must be corrected before the introduction of any flammable sample gas or application of power.

3.3.5.2 Manometer Method

Install a water-filled U-tube manometer at the sample gas outlet. Install a shut-off valve at the sample gas inlet. Admit air or inert gas to the inlet shut-off valve until the analyzer is pressurized to approximately 50 hPa. The water column will be about 500 mm.

10 psig

(69 kPa)

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–1

Flow Meter

Gas

Outlet

UCEM Analyzer

Inlet Outlet

Overpressure

approx. 50

INSTALLATION

Water

Figure 3-9. Leak Test Manometer Method

Close the inlet shut-off valve and, following a brief period for pressure equilibrium, verify that the height of the water column does not drop over a period of about 5 minutes. If the water column height drops, the system is leaking and must be corrected before the introduction of any flammable sample gas or application of power.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–2

3.3.5.3 Troubleshooting Leaks

INSTALLATION

Liberally cover all fittings, seals, and other possible sources of leakage with a suitable leak test liquid such as SNOOP

™

(part 837801). Bubbling or foaming indicates leakage. Checking for bubbles will locate most leaks but could miss some, as some areas are inaccessible to the application of SNOOP. For positive assurance that system is leak free, perform one of the preceding tests.

NOTE:

Refer to Specification in Preface for maximum pressure limitations.

For differential measurement, the leak check must be performed for the

measurement and reference side separately.

For analyzers with parallel gas paths, the leak check must be performed

for each gas path separately.

Figure illustrates MicroCEM analysis enclosure (Left) wire connections to the Sample Handling box

™

Trademark of NUPRO Company

Rosemount Analytical µCEM Continuous Analyzer Transmitter 3–3

INSTALLATION

4. Startup and Operation

4.1 Startup Procedure

Once the µCEM has been correctly assembled and installed in accordance with the instructions in Section 1.1, “

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4–1

STARTUP and OPERATION

Installation,” the analyzer is ready for operation. Before operating the system, verify that the Leak Checks have been

performed and that the sample handling unit is performing correctly. MicroCEM analysis enclosure On/Off switch is located inside the door on

the bottom right hand corner. Push switch to the “on” position to start system.

The unit will immediately run thru a self diagnostic mode. This may take up to 2 minutes. The user will know the system has passed all diagnostic test and is “ready” upon the green LED (located above on/off switch) flashing. If the green LED does not start to flash verify that proper power is connected to the unit and restart. If AC/Heater fan is running but the green LED still will not flash then call the factory immediately for help.

NOTE: After startup a warm-up time from 20 to 60 minutes (Depending upon ambient temp) is required for accurate measuements.

Analyzer operation can be confirmed by the green LED light flashing. The pocket pc can then be connected for viewing menus. Upon power up, the analyzer will perform a self-test routine. The test will take approximately 6 minutes.

4.2 Analyzer Operation

4.2.1 User Interface

The µCEM User Interface runs on a Pocket-PC with Windows CE operating system. It communicates with the µCEM via serial communication port. All input to the Pocket-PC is done using a pointing device that comes with the Pocket-PC. The Pocket PC can be plugged into two different ports. The first port is located on the front panel below the on/off switch inside the front door. The second port is from the bottom of the uCEM via J3 connector.

The pocket PC can be found behind the door behind the glass piece. Note that upon shipment the pocket PC may be located in a separate box.

To connect the pocket PC to the: µCEM via the inside connection.

1. Open µCEM door.

2. Plug RS232 plug into adapter located on front panel

3. Plug power supply cable into 5V adapter

4. Turn Pocket PC on

5. In order to assure no other windows are open press the reset button. Reset button is located on the back of the pocket PC.

6. Go to tools menu (Icon in upper left hand corner) and click on µCEMTS.

7. Unit will display data in 3 to 5 seconds. If unit does not show data in 3 to 5 seconds repeat procedure starting with number 5.

To connect the pocket PC to the: µCEM via the outside connection.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-1

STARTUP and OPERATION

1. Plug the external COM cable into J3 circular connector on the bottom of the uCEM.

2. Plug pocket pc RS232 plug into the J1 on the external COM cable.

3. Plug power supply cable into 5V plug on the COM cable.

4. Turn Pocket PC on.

5. In order to assure no other windows are open press the reset button. Reset button is located on the back of the pocket PC.

6. Go to tools menu (Icon in upper left hand corner) and click on µCEMTS.

7. Unit will display data in 3 to 5 seconds. If unit does not show data in 3 to 5 seconds repeat procedure starting with number 5.

Note: The Pocket PC can by used on any MicroCEM TS analysis enclosure regardless of the MicroCEM units IP address.

4.2.2 µCEM Main Window

The µCEM Main Window shown in Figure 4-1 provides the status of the three emissions channels. The status includes the current reading (updated approximately every 2 seconds), the last 1-minute average, and the last 15-minute average. The status column (Sts) indicates the status of the measurement and can be any of the values in the Table 4-1.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-2

Table 4-1 - Status Values

STARTUP and OPERATION

Shown in order of precedence. Maintenance mode status takes highest precedence.

Drag the edges of

the columns to

resize the columns

Status Description

M Indicates that maintenance mode is active.

C Calibration in process

I Invalid Reading. Indicates that the reading is

invalid due to calibration failure or Low Pressure

flow alarm. V Valid Reading P Customer Process Off Line (Dry contact by cust) B System is in By-Pass mode (Stream Switch)

O µCEM System powered off

Use the scrollbar to see the full set

of data

Figure 4-1 - µCEM Main Display

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-3

STARTUP and OPERATION

4.2.3 µCEM Menus

Lower left part of the µCEM screen contains three menus, from which all of the µCEM user-interface functions can be accessed. There are three main menus: File, Tools and Advanced, presented on Figures 4-2.1, 4-2.2, and 4-2.3.

File Menu: Provides General access to Connect, Log-in, Log Off features Tools Menu: Provides access to basic µCEM Tools, like alarms and stream switching Advanced Menu: Provides access to advanced µCEM Features, like Stream Settings

and User Toolbar Buttons: Shortcuts to Alarms, µCEM Settings, µCEM Admin, Stream Switching

Administration

Tools Menu: Provides

access to all functionality

Note: Exit will only be

available when current user has administrative access

Figure 4-2.1 - µCEM File Menu

Toolbar Buttons: Shortcuts

to Alarms, µCEM Settings, µCEM Admin., Data Logs and About

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-4

STARTUP and OPERATION

Figure 4-2.2 - µCEM Tools Menu

Figure 4-2.3 - µCEM Advanced Menu

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-5

STARTUP and OPERATION

4.2.4 µCEM Alarms

The µCEM Alarms dialog shows all the current alarms. A current alarm is one with an Active status of 1 (active) or an Acknowledged state of 0 (not acknowledged).. To see the historical Alarms for the last 3 months , the web based µCEM interface must be used. If one or more alarms are current, the most recent of them will be displayed on the main display. If more than one alarm is current “(more)” will be displayed after the name of the most recent alarm on the main window to indicate that more than one alarm is active. Horizontal scroll bar is be used to see Date and Time of the Alarms. Alarms can be General and Stream-specific. By selecting the radio buttons on the bottom, user can view different types of alarms.

Drag the edges of

the columns to

resize the columns

Use the scrollbar

to see the full set

of data

Figure 4-3. Pocket PC Alarms Screen

Alarms with a critical level will cause the System trouble output to become active when the alarm is active. When all active critical alarms are acknowledged, the System trouble output will become inactive.

Alarm Name Level Description Type

O2 Calibration Failed CO Calibration Failed NOx Calibration Failed

Critical O2 Calibration Failed to meet the

maximum Drift requirements

Critical CO Calibration Failed to meet the

maximum Drift requirements

Critical NOx Calibration Failed to meet the

maximum Drift requirements

Stream

Specific

Stream

Specific

Stream

Specific

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-6

STARTUP and OPERATION

O2 High Limit Critical O2 Sensor reading is above the

minimal acceptable limit

O2 Low Limit Critical O2 Sensor reading is below the

minimal acceptable limit

CO High Limit Critical CO Sensor reading is above the

minimal acceptable limit

CO Low Limit Critical CO Sensor reading is below the

minimal acceptable limit

NOx High Limit Critical NOx Sensor reading is above the

minimal acceptable limit

Nox Low Limit Critical NOx Sensor reading is below the

minimal acceptable limit

24V Over Max Critical 24V diagnostic input exceeds the

specified maximum

24 Low Min Critical 24V diagnostic input is below the

specified minimum

O2 Emission Limit Warning O2 reading is over the specified

Limit

CO Emission Limit Warning CO reading is over the specified

Limit

NOx Emission Limit Warning NOX reading is over the specified

Limit Converter Over Temp Converter Low Temp

Critical Converter temperature reading

exceeds the specified maximum

Critical Converter temperature reading is

below the specified minimum Zone Over Temp Critical Zone temperature reading

exceeds the specified maximum Zone Low Temp Critical Zone temperature reading is below

the specified minimum PDT Over Temp Critical Peltier Cooler (PDT) temperature

reading exceeds the specified

maximum PDT Low Temp Critical Peltier Cooler (PDT) temperature

reading is below the specified

minimum PMT Over Temp Critical PDD Chamber temperature

reading exceeds the specified

maximum PMT Low Temp Critical PDD Chamber temperature

reading is below the specified

minimum Low Pressure Critical Low Sample Flow Pressure is

detected (Below 2.5psi) Warmup Time Limit Critical System Warm-up process

exceeded the specified time limit

Stream

Specific

Stream

Specific

Stream

Specific

Stream

Specific

Stream

Specific

Stream Specific General

General

Stream Specific

Stream Specific General

General General General General

General

Stream Specific General

Table 4-2 – Alarm Summary

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-7

STARTUP and OPERATION

4.2.5 µCEM Login

The login dialog appears (Figure 4-4) when first requesting the µCEM Settings or µCEM Admin. If a valid user name and password are entered, the user logging in will have permission to use the µCEM Settings and/or the µCEM Administration (Refer to the User Settings page of the µCEM Settings dialog). After logging in the first time, it is not required again until the user logs out, or is logged out automatically because of a period of inactivity (Refer to the Auto Logout page of the µCEM Administration dialog).

Figure 4-4 - µCEM Login

On-screen keyboard is available at any time by clicking on the keyboard button.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-8

STARTUP and OPERATION

4.2.6 µCEM Login-Current User Indication

When a user is logged in, the µCEM main display will indicate the user name of the logged in user as shown in Figure 4-5.

Current user and Log off button.

Figure 4-5 - Current User Indication

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-9

STARTUP and OPERATION

4.2.7 Stream Switching Control

Typically a dual stream system is in Automatic Stream Switching mode. That means that it runs the timing schedule specified in User Settings Configuration file. If Automatic switching is not desirable, the user may turn it off using Tools-> Stop Auto Switching menu. In this case the system will remain on the current stream indefinitely. When Automatic switching is needed again, user may turn it back on with Tools->Start Auto Switching menu. The same task can be accomplished remotely, by clicking Stop Auto Switching button on the µCEM Real-Time Web page. Note, that this option is sustained even if the system is rebooted.

The operator may also force a switch between the streams at any time whether the system is in Auto-Switching mode or not. Tools menu has an option “Switch to StreamName”, where StreamName is a user-specified name of the stream. The same task can be accomplished remotely by clicking Switch to “StreamName” button on the µCEM Real-Time Web page.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-10

STARTUP and OPERATION

4.3 µCEM Settings

The µCEM Settings dialog is only available to users with µCEM Settings permission. If a user is not currently logged in, the login dialog will be displayed. If the current user doesn’t have µCEM Settings permission, µCEM will not allow Settings screen to appear. When the µCEM Settings are invoked from the Advanced menu or the µCEM Settings button, the µCEM Settings tabbed dialog is displayed. The Range page (tab) is displayed initially.

4.3.1 µCEM Settings-Range

The Range Settings page is used to specify the range for the analog outputs. Setting Range 2 to a value of 0 (zero) enables single range functionality and disables the dual range function. For Dual Range applications do not set range 2 equal too or

higher than Range 1 or the system will not calibrate properly. Note that Range 1 can be changed by the user but must be changed in the webrowser tools. See the Webrowser user settings section.

The dual range setting will enable the analyzer software and diagnostics to perform two separate performance curves for each range thus enhancing the measuring capabilities of the analyzer. A dual range setting is desired for applications burning dual fuels or that may display high dynamic reading between the low and high of the day. The analog outputs will also support the dual range mode. When the emission is below the Range 2 value, the analog output will switch to Range 2 mode and the Range 2 value becomes the full-scale value of the analog output. The range indication digital output will change to the Range 2 state. When the emission is above the Range 2 value, the output switches to Range 1 mode and the Range 1 value becomes the full-scale value of the output. The range indication digital output will change to the Range 1 state.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-11

STARTUP and OPERATION

pag

The Tabs allow selection of the

µCEM Settings

es.

Figure 4.6 - Range Settings

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-12

STARTUP and OPERATION

4.3.2 µCEM Settings-Auto Calibration

The Auto-Calibration settings are set on the Auto-Calibration page of the µCEM settings. If auto calibration is turned to the on position, then the user can select time and/or frequency of the auto calibration in the Auto Calibration Frequency tab (4.3.3). Note: Both manual and auto calibration need to be perform with the MicroCEM enclosure door in the closed position. If the door is opened then critical detector temperatures will vary which will cause a drift in the calibration. If the door is kept open long enough for temps to be constant at their setpoints then an open door calibration is acceptable. See section 4.7 “temp diagnostics”- for details on temperature setpoints.

Figure 4.7 - Auto Calibration Settings

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-13

STARTUP and OPERATION

4.3.3 µCEM Settings - Auto Calibration Time and Frequency

The Auto-Calibration Time and Frequency tab allows specifying time and frequency of the auto-calibration. Time field requires military time format. The times are displayed in Military time type.

Figure 4.8 - Auto Calibration Time and Frequency

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-14

STARTUP and OPERATION

4.3.4 µCEM Settings-Limits

The emission limits alarms can be set on the Limits page of the µCEM Settings. When a measured emission exceeds its limit, the emission will have a limit-exceeded status. This is indicated on the main display and on the Data-Logs display. It is also indicated in the limit exceeded digital output.

Figure 4.11 - Limit Settings

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-15

STARTUP and OPERATION

4.3.5 µCEM Settings-Calibration Gas

The Calibration Gas values and Gas Bottle allocation may be set on the Calibration Gas page of the µCEM Settings. This should be set whenever a Calibration Gas container is replaced or upon Startup of the system.

Calibration Gas Values: R1Mid: This is typically used for CGA audits and not for daily calibrations. The specific calibration gas mid value (typically between 40% to 60% of range) is set in this space. The MicroCEM will perform mid calibration on Range 1 on this gas but will not perform any corrections. This box should typically be left blank. It is mostly used as a check. R1Span: The specific calibration gas span value (typically between 80% to 100% of range) is set in this space for Range 1. A Nox range of 0-100ppm would typically use a gas bottle with 90ppm NOx balance N2. R2Mid: This is typically used for CGA audits and not for daily calibrations. The specific calibration gas mid value (typically between 40% to 60% of range) is set in this space. The MicroCEM will perform a mid calibration on Range 2 on this gas but will not perform any corrections. This box should typically be left blank. It is mostly used as a check. R2Span: The space is allocated for dual range applications. If the MicroCEM range setting is set for single range then the user will not be able to input any value into this space. The specific calibration gas span value (typically between 80% to 100% of range) is set in this space. A Nox range of 0-10ppm would typically use a gas bottle with 9ppm NOx balance N2.

Note that zero values do not have to be input into this page. For all zero calibrations the user must assure that the calibration gas used does not have any levels of the measurement gas in the cylinder. For example upon the analyzer zeroing O2, the bottle used must have 0% O2 in the Bottle. Zeroing the O2 is typically performed by using the NOx or CO Span gases.

Gas Bottle Allocation:

Gas 1, Gas 2 and Gas 3 are labels for the respective location of where the calibration gas cylinders are physically located on the external fittings.

Off: Designates that no operation will be performed. Zero: The MicroCEM will perform a zero calibration. R1Span: MicroCEM will perform a Span calibration for Range 1. R2Span: MicroCEM will perform a Span calibration for Range 2. Note that if a second range is NOT chosen in the range settings menu then user will not be able to input any value into this space. Range 2 should always be a lower value than range 1 if used. R1Mid: MicroCEM will perform a Mid Calibration for Range 1. R2Mid: MicroCEM will perform a Mid Calibration for Range 2. Note that if a second range is NOT chosen in the range settings menu then user will not be able to input any value into this space.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-16

STARTUP and OPERATION

Figure 4.12 - Calibration Gas Settings

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-17

STARTUP and OPERATION

4.3.6 µCEM Settings-Maintenance Mode

Maintenance mode may be selected for any of the emission types on the Maintenance Mode page of the µCEM Settings. Choosing maintenance mode will invoke an “M” flag” onto the data. Customer can perform routine maintenance while in this setting This mode is typically used when preventive maintenance is being performed. The M flag signifies to the EPA that the values reported are not valid therefore should not be applied to emissions reporting. Upon completion of Maintenance the user must go back into this screen to turn the Maintenance off. If not, the MicroCEM will continue to show the M flag in the data.

Figure 4.13 - Maintenance Mode Settings

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-18

STARTUP and OPERATION

4.3.7 µCEM -Manual Calibration

A dry-run Calibration may be initiated from the Manual Calibration page of the µCEM Settings by pressing the Manual Calibrate All icon. A full zero and span calibration will be run by the MicroCEM but the end result corrections of the calibration will not be applied to the O2/Nox/CO measurement values. If desired a partial calibration may be invoked for one or more of the emission types. While the manual calibration is in process, a calibration progress dialog will be displayed as shown in Figure 4.24. When the manual calibration is completed, the results are displayed in the Manual Calibration Results dialog as shown in Figure 4.10. If the Local Calibration checkbox is checked, the Local Calibration valve will be used during the calibration rather than the probe Calibration valve. Note that “Start Auto Cal now” will invoke a calibration and will apply new correction factor to all measurement when done.

Figure 4.9 - Manual Calibration Menu

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-19

STARTUP and OPERATION

4.3.8 Auto Calibration

The Auto Calibration dialog is displayed whenever calibration is in process. It displays the current emission values and the status of the calibration. The calibration may be canceled before it completes by pressing the Cancel button.

Note: The title of this dialog will read either “Auto Calibration” or “Manual Calibration” to indicate how the calibration process was initiated.

Figure 4.22 - Auto Calibration Status Screen

Use the scrollbar

to see the full set

of results

Figure 4.10 - Manual Calibration Results

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-1

STARTUP and OPERATION

4.4 µCEM Administration

The µCEM Administration dialog is only available to users with µCEM Administration permission. If a user is not currently logged in, the login dialog will be displayed. If the current user doesn’t have µCEM Administration permission, a message will be displayed which reads “Permission denied”. When the µCEM Administration is invoked from the Tools menu or the µCEM Administration button, the µCEM Administration tabbed dialog is displayed. The User Settings page (tab) is displayed initially.

4.4.1 µCEM Administration-User Settings

The user settings page of the µCEM Administration dialog allows users to be added, deleted or modified. Each user has a name, password, and permission settings. The permission settings include Settings permission that allows access to the µCEM Settings dialog, and Administrative permission that allows access to the µCEM Administration dialog. The Settings permission also allows a user to access the µCEM remotely using the web-based interface.

Figure 4.14 - User Settings

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-2

STARTUP and OPERATION

4.4.2 µCEM Administration-Auto Logoff

The number of minutes of inactivity after which a user is automatically logged off is set on the Auto Logoff page of the µCEM Administration.

Figure 4.15 - Auto Logoff

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-3

STARTUP and OPERATION

4.5 µCEM Factory and User Settings

A µCEM Factory and User Settings files are available for use by µCEM technicians to set parameters in the µCEM or a qualified customer technician. µCEM Settings are separated into two files: Factory Settings and User Settings. Factory Settings should be modified by a Rosemount technician only. Note: Some parameters in this file, if set incorrectly, may cause permanent damage to hardware.

User Settings can be modified by a qualified customer technician. User settings are accessible through the User Settings Web screen. See section 4.7 for details on access. Settings files are formatted as a standard Windows INI files. File is organized in sections (in square brackets). Configuration Parameters are presented in “Name = Value” format. Comments start with semicolon. User Settings files has three sections [General], [Stream 1] and [Stream 2]. The list of some settings is shown in Table 4.3 & Table 4.4. Consult a Rosemount factory person for details.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-4

STARTUP and OPERATION

Table 4.3 - [General] section

Calibration Setting Description

Stream1Time Stream 1 processing time in minutes when auto switching Stream2Time Stream 2 processing time in minutes when auto switching TransitionTime Time to keep the B flag after the switch have occurred, in

seconds Stream1Name Stream 1 Name to be shown on Pocket PC and Web pages Stream2Name Stream 2 Name to be shown on Pocket PC and Web pages CalibrationCurrentLoopOutputs Defines the behavior of Current Loops during Calibrations

1 - Hold the Last Good Value,

2 - Use the User-Specified Value

3 - Follow the Gases as is CalibrationCurrentLoopOutputsUserValue Value in milliamps. Used when the previous parameter is

set to 2 ByPassCurrentLoopOutputs Defines the behavior of Current Loops during By-Pass

1 - Hold the Last Good Value

2 - Use the User-Specified Value ByPassCurrentLoopOutputsUserValue Value in milliamps. Used when the previous parameter is

set to 2 AutoCalForcesSwitch Defines what to do, when the scheduled Auto-Calibration

time comes, but the system happens to process another

stream

1 - force a switch to the stream and run the Calibration

2 - wait until the stream is switching occures by itself and

run the Calibration DigitalOutputsLogic Defines how to control Digital Outputs

1- O2 Limit, CO Limit, NOX Limit Logic

2- Valid, In Calibration, In Maintenance

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-5

STARTUP and OPERATION

Table 4.4 - [Stream X] section

Stream Setting Description

DiluentCorrectionPercent Diluent Correction Percent used in calculations for the Stream O2R1Range Range 1 Setting for O2 (Range 2 can be changed from the Pocket PC) COR1Range Range 1 Setting for CO (Range 2 can be changed from the Pocket PC) NOXR1Range Range 1 Setting for NOx (Range 2 can be changed from the Pocket

PC)

PostCalibrationDelay Number of seconds to keep the C(Calibration) flag after the Auto

Calibration process is over

R1O2ZeroDriftLimit O2 Allowed Zero Drift

Limit for Range 1.

R1COZeroDriftLimit CO Allowed Zero Drift

Limit for Range 1.

R1NOXZeroDriftLimit NOx Allowed Zero Drift

Limit for Range 1.

R1OSMidDriftLimit O2 Allowed Mid Drift Limit

for Range 1.

R1COMidDriftLimit CO Allowed Mid Drift

Limit for Range 1.

R1NOXMidDriftLimit NOx Allowed Mid Drift

Limit for Range 1.

R1O2SpanDriftLimit O2 Allowed Span Drift

Limit for Range 1.

R1COSpanDriftLimit CO Allowed Span Drift

Limit for Range 1.

R1NOXSpanDriftLimit NOx Allowed Span Drift

Limit for Range 1.

R2O2ZeroDriftLimit O2 Allowed Zero Drift

Limit for Range 2.

R2COZeroDriftLimit CO Allowed Zero Drift

Limit for Range 2.

R2NOXZeroDriftLimit NOx Allowed Zero Drift

Limit for Range 2.

If the drift exceeds the allowed amount a drift alarm will occur, and the readings on the channel will no longer be valid until a successful calibration is completed.

R2OSMidDriftLimit O2 Allowed Mid Drift Limit

for Range 2.

R2COMidDriftLimit CO Allowed Mid Drift

Limit for Range 2.

R2NOXMidDriftLimit NOx Allowed Mid Drift

Limit for Range 2.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-6

STARTUP and OPERATION

R12O2SpanDriftLimit O2 Allowed Span Drift

Limit for Range 2.

R2COSpanDriftLimit CO Allowed Span Drift

Limit for Range 2.

R2NOXSpanDriftLimit NOx Allowed Span Drift

Limit for Range 2.

4.6 uCEM Data Logs

The µCEM maintains a minimum of 3 months of history in three types of data log files. The first type of log file is the measurement log, which contains emission measurements (at 1 minute intervals), alarm indications and maintenance mode indications. The second type of log file is the calibration log file, which contains information on each auto calibration done. The third is the alarm log file, which records any improperly functioning hardware. The data will be stored in flat, ASCII, CSV (comma-delineated) files. This file format can be read directly by MS Excel and imported into many types of software applications. The following parameters are factory set for each of the log file types.

4.6.1 Maximum Log File Size

This is how large a log file can get (in bytes) before it is closed and a new log file is opened.

Emissions Log: 1 MB Calib Log: 4000 bytes Alarm Log: 4000 bytes

4.6.2 Maximum Number of Log Files

This is how many log files can be created. When the maximum number of log files is reached, the oldest file is overwritten when new ones are created.

Emissions Log: 6 Calib Log: 6 Alarm Log: 6

4.6.3 Log File Name Format

The log file name uses the date that the file was created. It is of the format TYYYYMMDD.CSV where T is the log file type (E=Emissions, C=Calibration and A=Alarm), YYYY is the Year, MM is the month, and DD is the day of the month. For example, the file name E20010329.csv contains emissions data and was created on March 29, 2001.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-7

STARTUP and OPERATION

4.6.4 Measurement Log File Format

The log file contains data in a flat, ASCII, CSV file. The following are the fields of the file, in order of occurrence. The log file size will be about 42 bytes per entry. 3 months of data logs will require about 5,443,200 bytes

Name Description Example

Date/Time Month-day-year Hours:Minutes:Seconds 3-7-2001

10:24:00 O2 Percent O2 (percent) 10.5 O2 Limit O2 Limit exceeded alarm, 0=inactive,

1=active

O2 Status V=Valid, M=Maintenance Mode,

C=Calibration in process, I=Invalid

(calibration failed or sensor in failed state) CO CO parts per million 12 CO Limit CO Limit exceeded alarm, 0=inactive,

1=active CO Status V=Valid, M=Maintenance Mode,

C=Calibration in process, I=Invalid

(calibration failed or sensor in failed state) Nox NOx parts per million 15 NOx Limit NOx Limit exceeded alarm, 0=inactive,

1=active NOx Status V=Valid, M=Maintenance Mode,

C=Calibration in process, I=Invalid

(calibration failed or sensor in failed state)

0 V

Table 4.7 –Measurement Log File Format

4.6.5 Calibration Log File Format

The log file contains data in a flat, ASCII, CSV file. The following are the fields of the file, in order of occurrence. The log file size will be about 350 bytes per entry. 3 months of data logs will require about 32000 bytes (based on Calibration performed every 24 hours).

Name Description Example

Date/Time Calibration start

Gas 1 Time Time that Gas 1 started, Hours:Minutes:Seconds 10:25:30 Gas 2 Time Time That Gas 2 started, Hours:Minutes:Seconds 10:27:30 Gas 3 Time Time that Gas 3 started, Hours:Minutes:Seconds 10:28:30 Purge Time Time that the final purge started, Hours:Minutes:Seconds 10:30:30 Finish Time Time that the final purge finishes 10:31:00 O2 Expected Zero Expected percent O2 for Zero phase of calibration 0.0 O2 Measured Zero Measured percent O2 for Zero phase of calibration 0.0 O2 Zero Drift Percent drift of O2 zero calibration 0.0 O2 R1 Expected Mid

Span O2 R1 Measured Mid Measured percent O2 for Range 1 Mid span phase of

Month-day-year Hours:Minutes:Seconds

Expected percent O2 for Range 1 Mid span phase of calibration

3-7-2001 10:24:57

10.0

10.1

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-8

STARTUP and OPERATION

Span calibration O2 R1 Mid Drift Percent drift of O2 Range 1 mid calibration. 0.4 O2 R1 Expected Span

O2 R1 Measured Span

O2 R1 Span Drift Percent drift of O2 Range 1 span calibration 0.4 O2 R2 Expected Mid

Span O2 R2 Measured Mid

Span O2 R2 Mid Drift Percent drift of O2 Range 2 mid calibration. 0.4 O2 R2 Expected Span

O2 R2 Measured Span

O2 R2 Span Drift Percent drift of O2 Range 2 Span calibration 0.4 CO Expected Zero Expected ppm CO for zero phase of calibration 1 CO Measured Zero Measured ppm CO for zero phase of calibration 0 CO Zero Drift Percent drift of CO zero calibration -0.3 CO Expected R1 Mid

Span CO Measured R1 Mid

Span CO R1 Mid Span Drift Percent drift of CO Range 1 mid span calibration 0.3 CO R1 Expected Span Expected ppm CO for Range 1 span phase of calibration 45 CO R1 Measured Span Measured ppm CO for Range 1 span phase of calibration 45 CO R1 Span Drift Percent drift of CO Range 1 span calibration 0 CO Expected R2 Mid

Span CO Measured R2 Mid

Span CO R2 Mid Span Drift Percent drift of CO Range 2 mid span calibration 0.3 CO R2 Expected Span Expected ppm CO for Range 2 span phase of calibration 45 CO R2 Measured Span Measured ppm CO for Range 2 span phase of calibration 45 CO R2 Span Drift Percent drift of CO Range 2 span calibration 0 NOx Expected Zero Measured ppm NOx for zero phase of calibration 15 NOx Measured Zero Expected ppm NOx for zero phase of calibration 15 NOx Zero Drift Percent drift of NOx zero calibration 0 NOx Expected R1 Mid

Span NOx Measured R1 Mid

Span NOx R1 Mid Span Drift Percent drift of NOx Range 1 mid span calibration 0 NOx Expected R1 span

NOx Measured R1 span

Expected percent O2 for Range 1 Span phase of calibration

Measured percent O2 for Range 1 Span phase of calibration

Expected percent O2 for Range 2 Mid span phase of calibration

Measured percent O2 for Range 2 Mid span phase of calibration

Expected percent O2 for Range 2 Span phase of calibration

Measured percent O2 for Range 2 Span phase of calibration

Expected ppm CO for Range 1 mid span phase of calibration

Measured ppm CO for Range 1 mid span phase of calibration

Expected ppm CO for Range 2 mid span phase of calibration

Measured ppm CO for Range 2 mid span phase of calibration

Measured ppm NOx for Range 1 mid span phase of calibration

Measured ppm NOx for Range 1 span phase of calibration

20.2

20.3

10.0

10.1

20.2

20.3

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-9

STARTUP and OPERATION

NOx R2 Span Drift Percent drift of NOx Range 1 span calibration 0 NOx Expected R2 Mid

Span NOx Measured R2 Mid

Span NOx R2 Mid Span Drift Percent drift of NOx Range 2 mid span calibration 0 NOx Expected R2 span

NOx Measured R2 span

NOx R2 Span Drift Percent drift of NOx Range 2 span calibration 0

Table 4.8 – Calibration Log File Format

Measured ppm NOx for Range 2 mid span phase of calibration

Measured ppm NOx for Range 2 span phase of calibration

4.6.6 Alarm Log File Format

The log file contains data in a flat, ASCII, CSV file. The following are the fields of the file, in order of occurrence. The days or months maintained in the Alarm Log depends on how often trouble conditions are recorded. If alarms rarely occur, there is enough space for many years of alarm logs to be recorded.

Name Description Example

Date/Time Month-day-year Hours:Minutes:Seconds 3-7-2001 10:24:57 Fault Level 1=informational, 2=warning, 3=critical 3 Fault Type 0 = O2 Calibration Failed

1 = CO Calibration Failed **

2 = NOx Calibration Failed

3 = O2 High Limit

4 = O2 Low Limit

5 = CO High Limit **

6 = CO Low Limit **

7 = NOx High Limit

8 = NOx Low Limit

9 = O2 Emission Limit

10 = CO Emission Limit **

11 = NOx Emission Limit

12 = 5 Volt Fault **

13 = 6 Volt Fault **

14 = 24V Over Max

15 = 24 Low Min

16 = Converter Over Temp

17 = Converter Low Temp

18 = Converter On Failed **

19 = Converter Off Failed **

20 = Zone Over Temp

21 = Zone Low Temp

22 = Zone Heater On Failed **

23 = Zone Heater Off Failed **

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-10

Fault Description

24 = Zone Cooler On Failed **

25 = Zone Cooler Off Failed **

26 = Heater Fan On Failed **

27 = Heater Fan Off Failed **

28 = Cooler Fan On Failed **

29 = Cooler Fan Off Failed **

30 = PDT Over Temp

31 = PDT Low Temp

32 = PDT On Failed **

33 = PDT Off Failed **

34 = PMT Over Temp

35 = PMT Low Temp

36 = PMT On Failed **

37 = PMT Off Failed **

38 = O2 Over Temp **

39 = O2 Low Temp **

40 = O2 On Failed **

41 = O2 Off Failed **

42 = Warmup Time Limit

55 = Low Pressure

70 = IO Board Failed

71 = Disk Failure

72 = Network Failure

ASCII string describing fault. Up to 200

characters.

STARTUP and OPERATION

CO Calibration Failed

Table 4.9 – Alarm Log File Format

** - Alarm is not implemented in this version of software or reserved for the future use

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-11

STARTUP and OPERATION

4.6.7 Accessing the Real-Time ACSII Data String via Ethernet TCP/IP

(DAS)

Remote Real-time data acquisition from the uCEM is done through the TCP/IP enabled network via the HTTP (Web transport) protocol. Acquisition software has to request the page form the Web Server running on the uCEM unit with the desired frequency (real update time is 1 sec). URL for the real time data is defined as such: http://[uCEM IP]/fetchData.asp

For example: http://127.0.0.1/ fetchData.asp

In response Web Server will return the comma-delimited string that contains current analyzer data. Note: the response is a plain text not the HTML document. If the actual analyzer software is running, the response data will be formatted as such:

DateTime,O2CurrentValue,O2CurAlarms,O2Status,O21MinAverage,O21MinStatu s,O215MinAverage,O215MinStatus,COCurValue,COCurAlarms,COCurStatus,CO 1MinAverage,CO1MinStatus,CO15MinAverage,CO15MinStatus,NOxCurValue,N OxCurAlarms,NoxCurStatus,NOx1MinAverage,NOx1MinStatus,NOx15MinAverag e,NOx15MinStatus,ExtProcess1,ExtProcess2,DigInput1,DigInput2,DigInput3; AlarmsString

The result is a single string of data. DateTime is formatted as such: Month-Day-Year4Digits HoursMilitary:Minutes:Seconds Example: 02-05-2002 14:58:53 All the current and average gas values are the floating-point numbers and may contain a sign. Certain rules are defined for the current and average gas values: If there is a “#” sign in this field – data for this field are not valid. That usually means there is no data available or the data cannot be converted to the string representation (due for example to faulty Calibration).

If the value field shows – denotes that the system haven’t yet initialized the data. That usually happens when uCEM starts up and 1 minute or 15-minute averages are not yet available (calculated). Note that regardless of the status, values show the current measured data from the analyzer. “Magic number” means that the data (usually 15 minute averages) have not been yet calculated. ExtProcess1 and ExtProcess2 are the values of the Analog Inputs (Mega Watts and Fuel Flow usually). DigInput1, DigInput2, DigInput3- show the state of the digital inputs and can take a value of either 1(On) or 0(Off). DigInput1 is usually interpreted as ProcessOn. DigInput2 – as FlameOn. DigInput3 – as Shutdown. CurAlarms values show the current state of the emissions limit alarm associated with the gas. It’s an integer number that equals to 1 when emission limit for the gas is exceeded and stays 0 if the gas doesn’t gave associated alarm active.

All the Status values are single-character values. Status is defined as such: V – Valid I – Invalid

“-555.00” (negative 555.00). That is a “magic number” that

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-1

STARTUP and OPERATION

M – Maintenance C – Calibration P – Process Off O – uCEM Off

AlarmsString – is a string data that describes the current Alarms situation with the uCEM module. It is separated from the rest of the data by a semi-colon. AlarmsString usually is not parsed and used for the presentation purposes only. Example: “1,NOx Emission Failed. 13 More ...”

Example:

02-05-2002 14:58:53,21.44,1,V,20.09,V,-555.00,V,##.##,0,P,##.##,P,##.##,P,10.37,1,I,

12.45,I,-555.00,I,5.0,3.76,0,1,0;1,NOx Emission Failed. 13 More ...

This string means that the sample was taken February 5 2002 at 2:58PM, O2 values were all Valid except the 15 Minutes average was not yet calculated, CO process was Off - the data were not available. NOX data were Invalid and the 15 Minutes average was not yet calculated. Mega Watts value read from the input was 5.0, Fuel Flow – 3.76 DigInput1(ProcessOn) is set to 0(Off), DigInput2(FlameOn) is set to 1 (On), DigInput3(Shutdown) is set to 0 (Off) There were also 13 alarms active, NOx Emission Failed being the most recent one.

If the uCEM analyzer is not currently running the return string will be: “uCEM is not running. No data Available.”

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-2

STARTUP and OPERATION

4.7 Viewing Data via the Pocket PC Web Browser

The Pocket PC Web Browser menu can be accessed via the pocket pc main menu. In the top upper left hand corner of the menu the name of the unit will be displayed (ucem XXXX). Point on this name. A drop down menu will appear. Point on Internet Explorer. A sign on page will then be displayed. User name and password will be the identical as the normal names used on the administration settings. Very importantly the Web Browser function allows the user to access all data (calibrations, alarms, emission data logs, diagnostics) internally stored in the MicroCEM.

The Web Browser will show the following screens/options for the user. Note that these screens are updated once every 10 seconds unless the refresh bottom is pressed: Real Time: This screen is identical to the main menu screen normally shown on the pocket pc.

Emissions: This screen will enable the user to view all internal emission data logs stored in the MicroCEM. User can choose between 1, 15, 1hr or 24 hour periods. A designated time frame or most recent data can be choses. The report generator will display data in a chart type format showing each gas value and associated time along with data flags. The function is very helpful in very historical data or performing trouble shooting. Alarms: This screen will allow the user to display all alarms and time frames. User may choose time frames or most recent alarms.

Cal: Display of all calibrations with results can be viewed from this page. User Config: This file contains user selectable files that are typically input at startup

and never changed. See section 4.4 for details on descriptions. Note that reboot of the MicroCEM may be necessary for system to accept changed for several items in this file.

Factory Config: Do not access this file unless a certified Rosemount technician is present. Changes to this file may adversely affect or destroy the unit. Changes

made to this file without the written consent of the MicroCEM Product Manager will void the warranty. Download: User can easily download all data log files (Emissions, Alarms, Calibrations) stored in the MicroCEM. This is typically used when user is accessing the MicroCEM via a separate laptop or tabletop computer. See next section. Temp Diag: Temperature diagnostics is a very important tool for diagnosing existing problems or potential issues/problems with the MicroCEM. The following parameters will be shown: Temperature Parameter, Temp Setting, Actual Temp and Integral %. *Zone Temperature: Zone temperature is typically set to 47 degrees C. This is the temperature of the MicroCEM taken from the detector section thermocouple that is located behind the pressure gauge. This thermocouple is always used for systems with no CO. For systems with CO a thermocouple is located on the CO assy detector. The MicroCEM will typically control temperature to within +/- 1 degree C. Depending upon the outside ambient temperature the % on time can be from 0 to 100% on. If a negative value is shown in the integral then cooling is in process. Variations greater than 1 degree C will lead to gas measurement drifting. *PMD Temp: This is the Temperature of the chassis of the MicroCEM. Thermocouple is located in the PMD detector. Temperature is typically within 2 degrees C. of the zone. If the temperature drifts greater than this. Upon first turn on of the MicroCEM this temp can be monitored. Once this temp is within 2 degrees C of the Zone then the unit is ready for accurate measurements. Temperature above the 2 degree variance of the

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-1

STARTUP and OPERATION

zone may show than the AC/Heater unit fan may have failed or a possible defective thermocouple. *PDD Temp: For systems with NOx a cylindrical NOx detector assy is located in the detector section. Internal to the detector assy a small peltier device is operating and must operate at 0 degrees C. The temperature should never deviate +/- .05 degrees C from the setpoint of zero or the NOx readings may drift. Integral will typically run between 40 to 70%. *PMT Temp: This temperature is for the detector assy heater core. Setting is set to 52 degrees C. Temperature should not drift more than 0.2 degrees C or NOx drift may occur. Excessive temperature variation may be caused by either poor zone temperature control or a faulty heater. *Conv Temp: This temperature is for the NOx converter assembly. Temperature setting is 330 degrees C. Temp should not vary more than 1 degrees C. or NOx measurements will drift. A faulty heater will cause temp variations.

Note that when the enclosure door is opened that all of the above temperature setting may be affected and will take a short about of time to react and control to the desired temperatures.

Select 1 min., 15 min., 1 hour or 24 hour averages.

Figure 4.16 - View Data Logs

Table 4.10 - Average Period Selection

Average Period Time Range

Displayed

1 Minute 1 Hour 15 Minutes 1 Day 1 Hour 3 Days 24 Hours 3 Months

Note: The page header was scrolled out of view to show all the selection options, but it can be seen in Fi

If Most Recent is selected, the month day and hour do not need to be selected.

Select the ending hour to view (applicable only to 1 minute averages)

ure 4.17

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-2

STARTUP and OPERATION

Note: The Real-time, Config and Download are included in the navigation menu but these pages are intended for remote desktop use. As an enhancement these items could be hidden if the pages are browsed from a Windows CE version of Internet Explorer.

Alarms and Calibration data may also be viewed.

A Date is shown for 1 min or 15 minute averages. A date range is shown for 1 hour or greater averages.

The Emission DataLogs data is shown here.

7Figure 4.17 - View Data Logs Table

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-3

STARTUP and OPERATION

4.8 Viewing µCEM Data with an external PC Web Browser

The MicroCEM internal log files may be accessed using a user PC or laptop with a web browser that has access to the µCEM over a LAN, serial port connection (PPP) or Dialup Connection (RAS). The µCEM has Window CE Web Server installed and provides a Web-based interface to select and download the Data-Log files. The downloaded Data-Log files will be in a CSV (comma delineated ASCII) format. The log files may also be viewed as a web page in a tabular format.

1. Connect user PC or laptop to the MicroCEM via Ethernet LAN circular connector located on J4 connector. The Ethernet cable can then be routed to the users Ethernet hub where as many PC’s as desired can access the MicroCEM Web Browser. Customer may also choose to connect the cable directly to the Ethernet port located on the MicroCEMs PC104 PCB which is internal to the MicroCEM. Note that a crossover type Ethernet cable must be used if a hub is not utilized.

2. The user PC or laptop must have the same IP address as the MicroCEM or the MicroCEM IP address can be changed to the users desired IP address. Standard IP address of the MicroCEM is: 192.168.1.92

3. Once the IP addresses are matched the user can simply open internet explorer on their computer and type is the MicroCEMs IP address.

4. Once entered a user ID and password must be entered. These are the identical user ID and password as input into the administration menus.

5. Once entered the user can then access all pages as specified in section 4.7.

4.8.1 Real-Time Page

The Real-Time page provides a real-time display of the emission values and emission statuses. The display is refreshed every 10 seconds.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-1

STARTUP and OPERATION

Figure 4.18 - Real-Time Web Page

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-2

STARTUP and OPERATION

4.8.2 Emissions Page

The Emissions Page can be used to view emission history in a tabular web-page format. This page is used as part of the µCEM User interface as well as by a remote user (probably from a desktop computer).

If Most Recent is selected, the month day and hour do not need to be selected.

Select the ending hour to view (applicable only to 1 minute averages)

Select 1 min., 15 min., 1 hour or 24 hour averages.

Figure 4.19 – Emissions Selection

The Emission Data-Logs table is displayed (as shown in figure 4.19) after selecting the Date and Average Period and pressing the Display button. If desired a bookmark or shortcut may be made to the page displaying the table. In the future, the same table can be displayed by selecting this bookmark. If Most Recent Data was selected, the bookmarked page will always display Most Recent Data. If a specific date was specified, the book-marked page will always display the same date.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-3

STARTUP and OPERATION

Figure 4.20 - Emissions Table

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-4

STARTUP and OPERATION

Figure 4.21 - Calibration Table

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-5

STARTUP and OPERATION

4.8.3 Download Page

The download page of the µCEM allows the selection and download of the three types of Data-Logs. To quickly download recent data, a “Download Most Recent Emissions Data” selection is provided. For more control over the date range, a “Download Emissions by Date Range” selection is available. Once the selection is made, press the Download button to start the HTTP download. The µCEM will create a temporary file that contains the selected data. Due to memory limitations there is a limit to the number of files that can be downloaded simultaneously. If this limit is exceeded, a message will be displayed that reads “The simultaneous download limit has been reached, please try again later”.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-6

STARTUP and OPERATION

Download Emissions Log, Calibration Log or Alarm Log

Choose from:

1 Minute / 8 Hours 1 Minute / 1 Day 1 Minute / 1 Week 15 Minutes / 1 Day 15 Minutes / 1 Week 15 Minutes / 1 Month 15 Minutes / 3 Months 1 Hour / 1 Week 1 Hour / 1 Month 1 Hour / 3 Months

Figure 4.22 - Download Web Page

4.9 Viewing µCEM Data with MS Excel

The µCEM Data may be viewed with MS Excel. CSV comma delineated files can be opened either from the Web browser Session or after the file(s) are saved onto a workstation. The files may then be opened directly with Excel. These files later can be converted and saved in MS Excel native format to enable charting and other secondary analysis functions.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 4-7

MAINTENANCE and SERVICE

5. Maintenance and Service

CAUTION: QUALIFIED PERSONNEL

This equipment should not be adjusted or repaired by

anyone except properly qualified service personnel.

WARNING: PARTS INTEGRITY

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

WARNING: ELECTRICAL SHOCK HAZARD

Disconnect power to the module(s) prior to replacing components.

The uCEM Analyzer Module requires very little maintenance during normal operation.

5.1 Overview

The uCEM Analyzer Module requires very little maintenance during normal operation.

Occasionally, the detector's reaction chamber and sapphire window may require cleaning, refer to Section 5.7.

White crystal deposits on the windows of the reaction chamber and pl ugging of capillaries and vent are usually due to sample contaminates such as ammonia reacting with the high ozone levels and NO components. To eliminate the contaminates, the sampling system should be reworked or a preventive maintenance program developed (if dropout is not excessive). Another source of crystalline formation is contaminated air.

Several components may require replacement. These are discussed in the following sections.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-1

MAINTENANCE and SERVICE

Figure 5-2. uCEM Interconnect Diagram

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-2

MAINTENANCE and SERVICE

5.2 Converter

Refer to Figure 5-1, Item 97, and Figure 5-3. To replace the converter or sensor, disconnect the two pneumatic tubes and two electrical connections. Unlace the heater blanket, and remove the converter. Reassemble in reverse order, ensuring that the converter is oriented with the glass cloth at the bottom and the sensor is oriented correctly inside the heater jacket.

ASSEMBLED SIDE VI EW

Sensor

Heater Jacket

655228

Converter

Tube 655227

Glass

Cloth

Figure 5-3. Converter Assembly

5.3 Ozonator

Refer to Figure 5-1, item 98.To replace the ozonator, remove the gas fittings, the two large straps and all tie-wraps, and disconnect the one electrical connection. Reassemble in reverse order.

5.4 Personality Modules

There are seven different personality modules. Depending on your unit, you may have three, four five, six, or seven modules installed. These personality modules are installed on a custom backplane. see figure 5-4 for more information.

Tag each cable and its location before disconnecting any wiring. This helps in re-assembly

Wrap with aluminum foil

Sensor

655282

To remove any on the personality modules. Remove cables from the module to be removed, there are two screws at the bottom of each module. You will have to loosen each screw before you can remove the personality module.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-3

MAINTENANCE and SERVICE

Figure 5-4. Personality Modules and Backplane.

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-4

MAINTENANCE and SERVICE

5.5 Detector Assembly

Refer to Figure 5-5 and Figure 5-6.

REACTION CHAMBER REMOVAL:

Disconnect the stainless steel tubing lines at the Gyrolok fittings. Remove the (4) nuts holding the Detector Assembly to the chassis. Disconnect the plug from connector J1 on the Signal Board and remove the assembly from the chassis.

Note: Heatsink Compound. Care should be taken to avoid getting heatsink compound on optical surfaces. If this substance is removed during the disassembly process, a zinc-oxide-filled, silicone grease (e.g., Dow Corning 340 or EG&G Wakefield Engineering's Series 120 Thermal Joint Compound) be reapplied in the re-assembly of this component.

Although the heater and thermostat can be removed to facilitate handling, contact with the white heatsink compound can be minimized by leaving these items in place. Remove the (2) screws holding the top plate of the Detector , and move the plate along the wires and away from the Detector .

Remove the (2) screws holding the tube assembly in place. Hold the tubing with one hand while inverting the Detector Housing with the other, allowing the Reaction Chamber O-ring and window to be removed from below.

REACTION CHAMBER INSTALLATION:

To reinstall, hold the housing in the inverted position while sliding the Reaction Chamber O-ring and window into position and the tubing into the slot in the housing. Hold the Reaction Chamber in place while rotating the housing upright. Replace the hold-down screws.

Note: Component Positioning. The procedure described above is for the purpose of maintaining the relative positions of windows and O-ring to the Reaction Chamber during installation.

Replace the top cap and screws. Reverse the removal procedure to reinstall the Detector Assembly into the Analyzer Module.

PHOTODIODE REMOVAL:

Remove the Detector Assembly as described above. Invert the housing to access the mounting bracket. Remove the (3) screws and shoulder

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-5

MAINTENANCE and SERVICE

washers from the bracket. Remove the bracket, insulating disk and bottom plate as a unit to minimize the spread of the heatsink compound.

Remove the (2) screws holding the lower section of the Detector Housing, then slide the section along the cable and remove.

Remove the (2) screws holding the socket, thermistor and photodiode in place, being careful not to lose the washers that are used as shims.

Grasp the socket and photodiode base while slowly rotating to separate the photodiode from the housing. Some friction will be felt as an O-ring is used around the photodiode as a seal.

PHOTODIODE INSTALLATION:

To replace the photodiode, carefully remove the diode from the green socket, and replace with a new one. Before mounting the new diode, the top cap of the enclosure should be temporarily removed and the (2) screws holding the Reaction Chamber loosened about two turns. This allows air which is trapped between the O-ring seals to escape when the diode is inserted. It also maintains the position of the O-ring and window in the upper compartment.

The new photodiode should be slowly inserted into the housing while gradually rotating the body. This allows the O-ring to properly seat. Continue replacing screws, washers, thermistors, etc., with the thicker shim (washer) on the opposite side of the socket from the thermistor.

Replace the lower section of the housing, then the bottom cover, insulator and bracket with the shoulder washers and screws.

Re-tighten the screws in the Reaction Chamber (upper section). Replace the top cap and its screws.

To reinstall in the Analyzer Module, reverse the procedure for removal as indicated above.

Photodiode

Sapphire Window

Reaction Chamber

Thermistor

Assembly

Sample

Ozone

Exhaust

Photodiode Socket

ssembly

Detector Mounting Bracket

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-6

Heater

)

M3X0.5 x 16mm Screw (2) 3mm Spring Washer (2)

MAINTENANCE and SERVICE

M3X0.5 x 25mm Screw (2) 3mm Spring Washer (2)

Detector Header

Heater

Thermostat

Retainer Gasket

Reaction Chamber

Photodiode Cable

Insulator (between Lower Cover and Mounting Bracket)

Photodiode Case Ground

Heater/Thermostat Assembly 655235.

Tubing Cover

Lower Cover

Nylon Shoulder Washers (3)

M3X0.5 x 16mm Screw (3)

O-Ring 876478

Photodiode Assembly (see detail below)

M3X0.5 x 20mm Screw (2) 3mm Spring Washer (2)

Detector Cover

M3X0.5 x 16mm Screw (2) 3mm Spring Washer (2)

Photodiode

O-Ring 854540 Sapphire Window

Cushioning Gasket

Thermistor 655216

Thermistor Shim

Photodiode Socket Assembly

Thermistor Spacer

No. 6 Flat Washer (2

Assembly of Photodiode

Figure 5-6. Detector Assembly

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-7

MAINTENANCE and SERVICE

5.6 Central Processing Unit

The CPU is an Embedded Pentium-type AT Computer in 5.75” x 8” form factor. The peripherals integrated on board are: SVGA, 4 serial ports and one parallel port, Fast Ethernet ctrl., IDE, Keyboard, Mouse, 2 USB. The module is built around the Intel Tillamook processor and is equipped with 64MB SDRAM. The module also integrates one socket for SSD that performs like an HDD unit and can be used to store the operating system, the user’s programs and the data files. Other peripherals available on board are the Floppy disk controller, and the parallel port. The CPU is depicted in Figure 5-7.

Figure 5-7. CPU

5.6.1.1 Features Architecture: PC/AT Compatible

Dimensions: 5.75” x 8” Processor: Intel Tillamook processor - 266MHz Memory: 64 MB SDRAM Ram/Rom disk: 1 x 32 pin socket (max. 288MB) Operating System: WinNT BIOS: Standard with embedded extensions Interfaces: IDE ctrl

Floppy ctrl SVGA-CRT 10/100 Mbps Fast Ethernet

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-8

MAINTENANCE and SERVICE

2 USB ports 4 RS232 serial ports (one can be 485) Parallel port (bi-directional EPP-ECP) Keyboard PS/2 Mouse PS/2

Bus: AT bus according to PC/104 spec. Power Supply: AT/ATX Connectors: COM1-4, SVGA, USB 1 and 2, PS/2 Mouse/Keyboard,

ATX Power, Parallel, IDE, Floppy, and Fast Ethernet

5.6.1.2 EMBEDDED ENHANCED BIOS:

- Award, 256KB Flash Bios.The Bios is immediately activated when you first turn on the system. The Bios reads system configuratio information in CMOS RAM and begins the process of checking out the system.

5.6.2 Analog/Digital I/O Board

The Analog/Digital IO (ADIO) Board is an off-the-shelf, complete data acquisition system in a compact PC/104 packaging. The analog section contains 32 input channels, multiplexed A/D converter with 16 bit resolution and 10uS conversion time. Input ranges are +/-5v or +/- 10V. It also includes on-board DMA support. The analog output section includes two 12 bit D/A converters. Both sections features simplified calibration using on board programmable digital potentiometer. The digital I/O section provides 24 digital I/O lines, which feature high current TTL drivers. The board requires only +5V from the system power supply and generates its own +/-15V analog supplies on board. The board operates over the Extended Temperatures range of -25 to +85C. Figure 3 depicts the ADIO board and Figure 5-9 depicts the ADIO block diagram.

Figure 3-8. ADIO Board

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-9

MAINTENANCE and SERVICE

Figure 5-9. ADIO Block Diagram

5.6.2.1 Automatic Calibration

The ADIO board features automatic calibration of both analog inputs and outputs for enhanced accuracy and reliability. The potentiometers, which are subject to tampering and vibration, have been eliminated. Instead, all A/D calibration adjustments are performed using an octal 8-bit DAC. The DAC values are stored in an EEPROM and are recalled automatically on power up. The board includes three precision voltage references for negative full scale, zero, and positive full-scale. A calibration utility program provided with the board allows you to recalibrate the board anytime, in both unipolar and bipolar modes, and store the new settings in EEPROM. Autocalibration applies to the 4 D/A channels as well. The full-scale D/A range is selected with a jumper block. The analog outputs are fed back to the A/D converter so they can be calibrated without user intervention. Again, calibration settings are stored in EEPROM and automatically recalled on power-up.

5.6.2.2 Analog Inputs

The ADIO board provides split configuration capability, with more total input channels than any other PC/104 analog I/O board. The board can be user-configured in any of three ways:

Channels 32 32 single-ended 24 8 differential, 16 single-ended 16 16 differential

Format

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-10

MAINTENANCE and SERVICE

5.6.2.3 Programmable Input Ranges

A programmable gain amplifier, programmable unipolar/bipolar range, and programmable 5V/10V full-scale range combine to give the ADIO board a total of 10 different possible analog input ranges. All range settings are controlled in software for maximum flexibility.

Mode Full-

Scale

Unipolar 10V 1 0-10V 0.153mV Unipolar 5V 1 0-5V 0.076mV Unipolar 5V 2 0-2.5V 0.038mV Unipolar 5V 4 0-1.25V 0.019mV Unipolar 5V 8 0-0.625V 0.0096mV Bipolar 10V 1 ±10V 0.305mV Bipolar 5V 1 ±5V 0.153mV Bipolar 5V 2 ±2.5V 0.076mV Bipolar 5V 4 ±1.25V 0.038mV Bipolar 5V 8 ±0.625V 0.019mV

Gain Input

Range

Resolution

5.6.2.4 Enhanced Trigger and Sampling Control Signals

The ADIO board has an extra A/D trigger and sample control signals in the design. Seven auxiliary digital I/O lines on the analog I/O connector provide a sample/hold output signal, A/D trigger in and out lines (to enable synchronization of multiple boards) and external A/D clocking.

5.6.2.5 Analog Outputs

The ADIO board contains 4 12-bit analog outputs with autocalibration capability. Up to 5mA of output current per channel can be drawn from all channels simultaneously. Both unipolar and bipolar output ranges are supported with jumper configuration. And on power up, all outputs are reset to 0V automatically.

Mode

Full-Scale

Unipolar 10V 0-10V 2.44mV Unipolar 5V 0-5V 1.22mV

Bipolar 10V ±10V 4.88mV Bipolar 5V ±5V 2.44mV

Output Range

Resolution

5.6.2.6 FIFO and 16-Bit Bus Interface

An on-board 1024-byte FIFO enables the ADIO board to work with Windows 95 and NT by dramatically reducing the interrupt overhead. Each interrupt transfers 256 2-byte samples, or half the buffer, so the interrupt rate is 1/256 the sample rate. FIFO operation

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-11

MAINTENANCE and SERVICE

can be disabled at slow sample rates, so there is no lag time between sampling and data availability. The 16-bit interface further reduces software overhead by enabling all 16 A/D bits to be read in a single instruction, instead of requiring 2 8-bit read operations. The net result of this streamlined design is that the ADIO board supports gap-free A/D sampling at rates up to 200,000 samples per second, twice as fast as our previous boards.

5.6.2.7 Specifications

Analog Inputs

Number of inputs A/D resolution 16 bits (1/65,536 of full scale)

Bipolar ranges ±10V, ±5V, ±2.5V, ±1.25V, ±0.625V Unipolar ranges Input bias current 100pA max

Overvoltage protection

Nonlinearity ±3LSB, no missing codes Conversion rate 200,000 samples/sec.max On-board FIFO 1K x 8(512 16-bit samples) Calibration Automatic;values stored in EEPROM

Analog Outputs

Number of outputs 4 D/A resolution 12 bits (1/4096 of full scale) Output ranges ±5, ±10, 0-5, 0-10 Output current ±5mA max per channel Settling time 6µS max to 0.01% Relative accuracy ±1 LSB Nonlinearity ±1 LSB, monotonic Reset All channels reset to OV

Calibration Digital I/O

Main I/O 24 programmable I/O Input current ±1µA max

32 single-ended, 16 differential, or 16 SE + 8 DI; user selectable

0-10V, 0-5V, 0-2.5V, 0-1.25V, 0.625V,

±35V on any analog input without damage

Automatic; values stored in EEPROM

Output current

Logic 0 Logic 1

Auxilary I/O 4 inputs, 4 outputs, optional use as

Rosemount Analytical µCEM Continuous Analyzer Transmitter 5-12

64mA max per line

-15mA max per line

Rosemount MicroCEM TS Analysis Enclosure-Rev 2.1 Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual