Rosemount Model 500 Gas Chromatograph Hardware Reference Rev K Manuals & Guides

Model 500

Gas Chromatograph

Hardware Reference Manual

Part Number 3-9000-537

Revision K

JULY 2010

Model 500 Gas Chromatograph

System Reference Manual

NOTICE

ROSEMOUNT (“SELLER”) SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS IN
THIS MANUAL OR OMISSIONS FROM THIS MANUAL. SELLER MAKES NO WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND, IN NO EVENT,
SHALL SELLER BE LIABLE FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING,
BUT NOT LIMITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, ETC.

PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER IDENTIFICATION
ONLY AND MAY BE TRADEMARKS/REGISTERED TRADEMARKS OF THESE COMPANIES.

THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORMATIONAL PURPOSES
ONLY, AND WHILE EVERY EFFORT HAS BEEN MADE TO ENSURE THEIR ACCURACY, THEY
ARE NOT TO BE CONSTRUED AS WARRANTIES OR GUARANTEES, EXPRESSED OR IMPLIED,
REGARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR
APPLICABILITY. WE RESERVE THE RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR
SPECIFICATIONS OF SUCH PRODUCTS AT ANY TIME.

SELLER DOES NOT ASSUME RESPONSIBILITY FOR THE SELECTION, USE OR MAINTENANCE
OF ANY PRODUCT. RESPONSIBILITY FOR PROPER SELECTION, USE AND MAINTENANCE OF
ANY SELLER PRODUCT REMAINS SOLELY WITH THE PURCHASER AND END-USER.

THE ROSEMOUNT LOGO IS A REGISTERED TRADEMARK OF ROSEMOUNT, INC. THE
EMERSON LOGO IS A TRADEMARK AND SERVICE MARK OF EMERSON ELECTRIC CO.

COPYRIGHT

All rights reserved. No part of this work may be reproduced or copied in any form or by any
means - graphic, electronic, or mechanical — without first receiving the written permission of
Rosemount, Inc. Shakopee, MN. U.S.A.

©

2010 BY Rosemount, HOUSTON, TX U.S.A.

WARRANTY

1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as
otherwise expressly provided herein, Rosemount, (“Seller”) warrants that the firmware will
execute the programming instructions provided by Seller, and that the Goods manufactured or
Services provided by Seller will be free from defects in materials or workmanship under
normal use and care until the expiration of the applicable warranty period. Goods are
warranted for twelve (12) months from the date of initial installation or eighteen (18) months
from the date of shipment by Seller, whichever period expires first. Consumables and Services
are warranted for a period of 90 days from the date of shipment or completion of the Services.
Products purchased by Seller from a third party for resale to Buyer ("Resale Products") shall
carry only the warranty extended by the original manufacturer. Buyer agrees that Seller has no
liability for Resale Products beyond making a reasonable commercial effort to arrange for
procurement and shipping of the Resale Products. If Buyer discovers any warranty defects and
notifies Seller thereof in writing during the applicable warranty period, Seller shall, at its option,
promptly correct any errors that are found by Seller in the firmware or Services, or repair or
replace F.O.B. point of manufacture that portion of the Goods or firmware found by Seller to
be defective, or refund the purchase price of the defective portion of the Goods/Services. All
replacements or repairs necessitated by inadequate maintenance, normal wear and
usage, unsuitable power sources, unsuitable environmental conditions, accident, misuse,
improper installation, modification, repair, storage or handling, or any other cause not the fault
of Seller are not covered by this limited warranty, and shall be at Buyer's expense. Seller shall
not be obligated to pay any costs or charges incurred by Buyer or any other party except as
may be agreed upon in writing in advance by an authorized Seller rep-resentative. All costs of
dismantling, reinstallation and freight and the time and expenses of Seller's personnel for site
travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in
writing by Seller. Goods repaired and parts replaced during the warranty period shall be in
warranty for the remainder of the original warranty period or ninety (90) days, whichever is
longer. This limited warranty is the only warranty made by Seller and can be amended
only in a writing signed by an authorized representative of Seller. Except as otherwise expressly
provided in the Agreement, THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY
KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR
PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. It

is understood that corrosion or erosion of materials is not covered by our guarantee.

2. LIMITATION OF REMEDY AND LIABILITY: SELLER SHALL NOT BE LIABLE FOR DAMAGES
CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF
WARRANTY HEREUNDER SHALL BE LIMITED TO REPAIR, CORRECTION, REPLACEMENT OR
REFUND OF PURCHASE PRICE UNDER THE LIMITED WARRANTY CLAUSE IN SECTION 1
HEREIN. IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION
(WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER
TORT OR OTHERWISE), SHALL SELLER'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS
EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED OR SERVICES
PROVIDED BY SELLER GIVING RISE TO THE CLAIM OR CAUSE OF ACTION. BUYER AGREES
THAT IN NO EVENT SHALL SELLER'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXTEND
TO INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. THE TERM
"CONSEQUENTIAL DAMAGES" SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF
ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE AND COST OF CAPITAL.

IMPORTANT INSTRUCTIONS

• Read all instructions prior to installing, operating, and servicing this product.

• Follow all warnings, cautions, and instructions marked on and supplied with this product.

• Inspect the equipment packing case and if damage exists, notify your local carrier for
liability.

• Open the packing list and carefully remove equipment and spare or replacement parts
from the case. Inspect all equipment for damage and missing parts.

• If items are damaged or missing, contact the manufacturer at 1 713 396 8880 for
instructions about receiving replacement parts.

• Install equipment as specified per the installation instructions and per applicable local and
national codes. All connections shall be made to proper electrical and pressure sources.

• Ensure that all equipment doors are closed and protective covers are in place, except
when maintenance is being performed by qualified persons, to prevent personal injury.

• Use of this product for any purpose other than its intended purpose may result in property
damage and/or serious injury or death.

• Before opening the flameproof enclosure in a flammable atmosphere, the electrical
circuits must be interrupted.

• Repairs must be performed using only authorized replacement parts as specified by the
manufacturer. Use of unauthorized parts can affect the product's performance and place
the safe operation of the product at risk.

• When installing or servicing ATEX-certified units, the ATEX approval applies only to
equipment without cable glands. When mounting the flameproof enclosures in a
hazardous area, only flameproof cable glands certified to IEC 60079-1 must be used.

• Technical assistance is available 24 hours a day, 7 days a week by calling 1 713 396 8880.

This page is intentionally left blank.

TABLE OF CONTENTS

DESCRIPTION 1.1 PURPOSE OF THIS MANUAL ..........................1-1

1.1.1 Section 1 Description ...................................1-1

1.1.2 Section 2 Equipment Description....................1-1

1.1.3 Section 3 Installation and Startup...................1-1

1.1.4 Section 4 Operation......................................1-1

1.1.5 Section 5 Maintenance .................................1-2

1.1.6 Section 6 Recommended Spare Parts..............1-2

1.1.7 Appendices ..................................................1-2

1.2 INTRODUCTION............................................1-2

1.3 FUNCTIONAL DESCRIPTION...........................1-4

1.4 MODES OF OPERATION.................................1-6

1.4.1 User Interfaces .............................................1-6

EQUIPMENT

DESCRIPTION

1.4.2 Capabilities...................................................1-6

1.5 THEORY OF OPERATION ...............................1-7

1.5.1 The Analyzer Detector ...................................1-7

1.5.2 Data Acquisition .........................................1-10

1.5.3 Peak Detection ...........................................1-11

1.5.4 Basic Analysis Computations ........................ 1-12

1.6 GLOSSARY ................................................1-16

2.1 SAMPLING SYSTEM......................................2-1

2.1.1 Sampling Point Location.................................2-2

2.1.2 Sample Volume and Flow Rate........................2-2

2.1.3 Sample Conditioning......................................2-3

2.1.4 Contamination Precautions .............................2-3

2.1.5 Valving ........................................................2-3

2 TABLE OF CONTENTS

Model 500

2.1.6 Calibration Gas .............................................2-4

2.2 ANALYZER...................................................2-5

2.2.1 Physical Description ......................................2-5

2.2.2 Chromatograph Valves................................... 2-7

2.2.3 Detector Subsystem ...................................... 2-8

2.2.4 Analyzer Preamplifier Unit ..............................2-9

2.2.5 Analyzer Specifications ..................................2-9

2.2.6 Utility Gas Requirements .............................. 2-10

2.3 CONTROLLER ............................................. 2-10

2.3.1 Controller Hardware Configurations ...............2-12

2.3.2 Optional Keypad and Display ........................ 2-25

2.3.3 Alarm Specifications.................................... 2-26

INSTALLATION AND

SETUP

3.1 PRECAUTIONS AND WARNINGS .................... 3-3

3.1.1 Hazardous Environments ................................3-4

3.1.2 Power Source Wiring .....................................3-5

3.1.3 Signal Wiring ................................................3-6

3.1.4 Electrical and Signal Ground ...........................3-8

3.1.5 Electrical Conduit ........................................ 3-10

3.1.6 Sample Systems Requirements ..................... 3-11

3.2 PREPARATION............................................ 3-12

3.2.1 Introduction................................................ 3-12

3.2.2 Site Selection .............................................3-13

3.2.3 Unpacking the Unit...................................... 3-14

3.2.4 Necessary Tools and Components................. 3-15

3.2.5 Optional Tools and Components.................... 3-16

3.3 INSTALLING THE ANALYZER .......................3-18

3.3.1 Point-to-point Wiring Guide,

Analyzer-Controller...................................... 3-18

Installation and Setup JULY 2010

Model 500

TABLE OF CONTENTS 3

3.3.2 Analyzer AC Power Wiring ........................... 3-26

3.3.3 Sample and Gas Lines..................................3-27

3.4 INSTALLING THE GC CONTROLLER ..............3-30

3.4.1 Modbus Slave Address (COM ID) Setup .........3-30

3.4.2 Controller-Analyzer Wiring ............................3-35

3.4.3 Controller PC Wiring (Serial Connections) .......3-37

3.4.4 CPU and COM4A Serial Communications

Setups .......................................................3-45

3.4.5 Controller Printer Wiring ...............................3-69

3.4.6 Discrete (Digital) I/O Wiring ..........................3-71

3.4.7 Analog I/O Wiring........................................3-74

3.4.8 Controller AC Power Wiring.......................... 3-77

OPERATION FROM

LOCAL KEYPAD AND

DISPLAY

3.5 ANALYZER LEAK CHECKS AND PURGING FOR

FIRST CALIBRATION ...................................3-78

3.5.1 Analyzer Leak Checks.................................. 3-78

3.5.2 Purging Carrier Gas Lines ............................. 3-80

3.5.3 Purging Calibration Gas Lines........................3-83

3.6 SYSTEM START-UP ....................................3-85

4.1 INTERFACE COMPONENTS FOR LOCAL DATA

DISPLAY AND ENTRY....................................4-3

4.1.1 Light Emitting Diode (Led) Indicators................ 4-3

4.1.2 Liquid Crystal Display (LCD) ...........................4-4

4.1.3 Keypad ........................................................4-4

4.2 LOGGING ON TO VIEW OR EDIT DATA ...........4-6

4.2.1 First Time Log-On..........................................4-6

4.2.2 Subsequent Log-On .......................................4-7

4.2.3 Start / Halt an Auto Sequence Analysis............4-8

4.2.4 Editing Procedures....................................... 4-10

4.2.5 Validity Checks of Data Entries .....................4-11

JULY 2010 Operation from Local Keypad and Display

4 TABLE OF CONTENTS

MAINTENANCE 5.1 TROUBLESHOOTING AND REPAIR CONCEPT ...5-2

Model 500

4.3 LOCAL DISPLAY MENUS ............................. 4-12

4.3.1 Main Menu .................................................4-14

4.3.2 Hardware Menu ..........................................4-14

4.3.3 Operator Entries Menu ................................. 4-15

4.3.4 Alarms Menu ..............................................4-16

4.3.5 Chromatogram Menu ................................... 4-16

4.3.6 GC Control Menu ........................................ 4-16

4.3.7 Data Records Menu ..................................... 4-17

4.3.8 Config Rpt - Maint. Log Menu....................... 4-17

5.2 ROUTINE MAINTENANCE...............................5-3

5.2.1 Model 500 Maintenance Checklist...................5-4

5.2.2 Routine Maintenance Procedures.....................5-5

5.2.3 Contract Service ...........................................5-5

5.3 LOCATING AND GAINING ACCESS TO EQUIPMENT

ELEMENTS ...................................................5-5

5.3.1 Analyzer Electrical/Electronic Units .................. 5-5

5.3.2 Detector Elements, Heater Elements, Valves and

Columns ......................................................5-7

5.4 PRECAUTIONS FOR HANDLING PRINTED CIRCUIT

ASSEMBLIES ................................................ 5-7

5.5 SERVICE, TROUBLESHOOTING, AND REPAIR

INSTRUCTIONS ............................................5-8

5.5.1 Preamplifier ................................................5-10

5.5.2 Temperature Control.................................... 5-10

5.5.3 Decoder .....................................................5-10

5.5.4 Analyzer Troubleshooting Guide .................... 5-13

5.5.5 Chromatograph Valves................................. 5-22

5.5.6 Detector Bridge Balance ...............................5-23

Maintenance JULY 2010

Model 500

TABLE OF CONTENTS 5

5.5.7 Temperature Measurements .........................5-25

5.5.8 Measure Vent Flow (MV) .............................5-27

5.5.9 Analog Inputs ............................................. 5-27

5.6 GC CONTROLLER MAINTENANCE................. 5-28

5.6.1 GC Controller Access...................................5-29

5.7 COMMUNICATIONS ....................................5-30

5.7.1 GC Controller Address Change...................... 5-31

5.8 ANALOG INPUTS AND OUTPUTS ................. 5-31

5.8.1 Analog Output Dialog Description.................. 5-32

5.8.2 Changing a Variable.....................................5-34

5.8.3 Changing the Bargraph.................................5-35

5.8.4 Performing a Manual Calibration.................... 5-37

RECOMMENDED SPARE

PARTS

5.8.5 Performing an Automated Calibration............. 5-39

5.8.6 Analog Loopback Test Circuits......................5-41

5.8.7 Upgrading Analog Outputs ...........................5-43

5.9 DISCRETE (DIGITAL) INPUTS AND OUTPUTS . 5-44

5.9.1 Digital Loopback Test Circuit ........................5-44

5.10 FUSE PROTECTION ..................................... 5-45

5.11 ANALYZER-CONTROLLER INTERCONNECT ....5-46

5.11.1 Function Codes........................................... 5-48

6.1 ANALYZER SPARES ......................................6-1

6.1.1 Printed Circuit Card Assemblies (Analyzer) .......6-1

6.1.2 Electrical and Mechanical Assemblies (Analyzer)6-1

6.2 GC CONTROLLER SPARES .............................6-3

6.2.1 Printed Circuit Card Assemblies

(GC Controller)..............................................6-3

6.2.2 Electrical and Mechanical Components (GC

Controller) ....................................................6-3

JULY 2010 Recommended Spare Parts

6 TABLE OF CONTENTS

Model 500

APPENDIX A,

SUPPLEMENTAL

WIRING GUIDE - SERIAL

COMMUNICATIONS

A.1 GC SERIAL PORT AND CABLE CONFIGURATIONS

FOR RS-232 .................................................A-1

A.2 RS-232 CONNECTION FROM GC CONTROLLER TO

PC...............................................................A-4

A.2.1 DB-9 Serial Port of GC to DB-9 Port of PC........A-4

A.2.2 DB-9 Serial Port of GC to DB-25 Port of PC ......A-5

A.2.3 Phoenix Plug Port of GC to DB-9 Port of PC......A-6

A.2.4 Phoenix Plug Port of GC to DB-25 Port of PC....A-7

A.3 RS-232 CONNECTION FROM GC CONTROLLER TO

EXTERNAL MODEM ......................................A-8

A.3.1 DB-9 Serial Port of GC to DB

Modem

........................................................A-8

A.3.2 Phoenix Plug Port of GC to DB-25 Port

Modem

........................................................A-9

-25 Port of

of

A.4 EXAMPLE RS-422 CONNECTION FROM PC TO

GC ............................................................A-10

APPENDIX B,

MANIFOLD FOR TWO

CARRIER GAS BOTTLES

TO GC SYSTEM

APPENDIX C, GUIDE TO

TRANSIENT

PROTECTION MODULES

A.5 EXAMPLE RS-485 CONNECTION FROM PC TO

GC ............................................................A-12

A.6 JUMPER-BASED SERIAL CHANNEL

CONFIGURATIONS......................................A-15

B.1 ILLUSTRATION ............................................. B-2

B.2 INSTALLATION AND LINE PURGING................ B-3

B.3 REPLACING CARRIER CYLINDER ....................B-4

C.1 PURPOSE OF THE TRANSIENT PROTECTION

MODULES....................................................C-1

C.2 PART APPLICATIONS, NUMBERS, AND

DESCRIPTIONS.............................................C-2

Appendix A, Supplemental Wiring Guide - Serial Communications JULY 2010

Model 500

APPENDIX D, INTERNAL

MODEM FOR GC

CONTROLLER

APPENDIX E, SETTING

SOLENOID PURGE

FLOWS

TABLE OF CONTENTS 7

C.3 TROUBLESHOOTING TRANSIENT PROTECTION

MODULES ....................................................C-4

APPENDIX F,

UPGRADING FROM

2251 TO 2350A GC

CONTROLLER

APPENDIX G, 2350 TO

2350A CPU RETROFIT

INSTRUCTIONS

F.1 HALT CURRENT ANALYSIS AND POWER

DOWN .........................................................F-1

F.2 NOTE EXISTING WIRING CONNECTIONS TO

2251 ...........................................................F-2

F.3 REMOVE CABLES, REPLACE CONTROLLER, AND

RECONNECT ................................................ F-5

G.1 2350A CPU ASSEMBLY INTRODUCTION........ G-1

G.2 CONVERSION PROCESS ............................... G-2

G.3 BASIC 2350A CONFIGURATION .................... G-7

G.4 2350A OPTIONS.......................................... G-9

G.4.1 The COM4A Board ....................................... G-9

G.5 TO ADD A MODEM .....................................G-12

G.6 TO ADD AN ETHERNET CARD......................G-15

APPENDIX H, 2350A

H.1 INTRODUCTION........................................... H-2

(LX-800) CPU RETROFIT

INSTRUCTIONS

H.2 REMOVING THE OLD CPU CARD ................... H-4

H.3 INSTALLING THE NEW CPU BOARD ............... H-6

H.4 INSTALLING A KEYBOARD AND DISPLAY WITH

COM4A BOARD........................................... H-7

JULY 2010 Appendix D, Internal Modem for GC Controller

8 TABLE OF CONTENTS

APPENDIX F, SHIPPING

AND LONG-TERM

STORAGE

RECOMMENDATIONS

ADDENDUM 1

ADDENDUM 2

Model 500

H.5 INSTALLING A KEYBOARD AND DISPLAY

WITHOUT COM4A BOARD.............................H-9

H.6 RETROFITTING THE ANALOG BOARD ...........H-11

H.6.1 Identifying your Analog Board .......................H-11

H.6.2 Installing a New Analog Board ......................H-13

H.7 REASSEMBLING THE 2350A ........................H-13

Appendix F, Shipping and long-term storage recommendations JULY 2010

DESCRIPTION

1.1 PURPOSE OF THIS MANUAL

This manual (P/N 3-9000-537) is intended as a user's guide to accompany
the Model 500 gas chromatograph.

For software operation instructions, see the MON2000 Software for
Gas Chromatographs User Manual (P/N 3-9000-522)

This manual provides the following information:

1.1.1 Section 1 Description

• A general description of the Model 500 gas chromatograph (GC) and
its components, their configurations and functions.

• A brief description of the GC's software, user interface, and
capabilities.

• Introduction to GC theory of operation and terminology.

1.1.2 Section 2 Equipment Description

• Guidelines for sampling system and gas connections.

• Descriptions of Analyzer subsystems and components.

• Descriptions of GC Controller subsystems and components.

1.1.3 Section 3 Installation and Startup

Instructions for installing the GC hardware.

1.1.4 Section 4 Operation

Instructions for operating the GC by means of its built-in keypad and
liquid crystal display (LCD), if provided.

1-2 Description

1.1.5 Section 5 Maintenance

• Instructions for regular maintenance and care of the GC hardware.

• Instructions for troubleshooting, repair, and service of the GC
hardware.

1.1.6 Section 6 Recommended Spare Parts

List of boards, valves, and other components suggested as spare parts.

1.1.7 Appendices

Appendices with additional, helpful reference materials and drawings.

1.2 INTRODUCTION

The Model 500 GC is a high-speed gas chromatograph that is factory
engineered to meet specific field application requirements based on
typical stream composition and the anticipated concentration of the
components of interest. The Model 500 typically consists of three major
components, the Analyzer Assembly, the Controller, and the Sample
Conditioning System:

Model 500 Gas Chromatograph

Analyzer Assembly (Model 500 Series) - Located near the sample tap.
The Analyzer includes GC columns, detectors, preamplifier, stream
switching valves, and solenoids. The Model 500 Analyzer is housed in a
National Electrical Manufacturers Association (NEMA) 7, National
Electrical Code (NEC) Class I, Division 1, Groups B, C, and D approved
enclosure, for use in a hazardous environment.

GC Controller - Located no further than 2000 feet (610 meters) away
from the Analyzer. The GC Controller includes electronics and ports for
signal processing, instrument control, data storage, personal computer
(PC) interface, and telecommunications. The GC Controller is available
in various enclosures and configurations, as follows:

Explosion Proof - NEMA 4X (weatherproof and corrosion resistant) and
NEMA 7, NEC Class I, Division 1, Groups B, C, and D approved
enclosure, for use in a hazardous environment. Available with or without
a built-in keypad and liquid crystal display (LCD).

Section 5 Maintenance JULY 2010

Model 500 Gas Chromatograph

Rack Mount - Suitable for use in a nonhazardous environment. Made
for mounting on a standard 19 inch rack. Available with or without a
built-in keypad and LCD.

Retrofit - Suitable for use in a nonhazardous environment. Made for
mounting on a 12-inch rack previously sold for 2251 GC Controller. The
Retrofit enclosure is not available with a built-in keypad and LCD
(therefore, a PC is required for operating).

Sample Conditioning System (SCS) - Located between the process
stream and the Analyzer sample inlet, usually mounted on the lower
portion of the Analyzer stand. The standard configuration SCS includes
a mounting plate, block (or shutoff) valves, and filters. Optionally, the
SCS can be configured with Genie® bypass filters, liquid shut-off valves,
and optional solenoids for stream switching: all of which can be enclosed
in an electric (heat tape design) oven.

Description 1-3

In its standard configuration, the Model 500 Analyzer can handle up to
five streams: typically, four for sample and one for calibration. With an
optional stream switch assembly added, the Model 500 Analyzer can
switch up to twelve streams, maximum.

The GC Controller, is designed to be operated primarily from a personal
computer (PC) running the MON2000 Software package. This provides
the user with the greatest capability, ease-of-use, and flexibility. One PC
running MON2000 can connect with up to 32 gas chromatographs. The
PC is used to display chromatograms and reports, which can then be
stored as files on the PC, or printed from either the PC's or the GC's
printer.

Also, each individual GC can be operated from its built-in keypad and
LCD (if installed in that configuration); however, this method offers more
limited functions. Display of the chromatograms on the LCD is
accomplished in scrolling strip chart fashion.

Since neither the PC nor a normal printer can be placed in a hazardous
area, serial port and Modbus communications links are provided for
connecting the Model 500 Analyzer to the PC, other computers, printers,
chromatographs, and Controllers.

JULY 2010 INTRODUCTION

1-4 Description

1.3 FUNCTIONAL DESCRIPTION

A functional block diagram of a typical Model 500 Analyzer installation is
shown in Figure 1-1. A sample of the gas to be analyzed is taken from the
process stream by a sample probe installed in the process line. The
sample passes through a sample line to the sample conditioning system
where it is filtered or otherwise conditioned. After conditioning, the
sample flows to the Analyzer for separation and detection of the
components of the gas.

The chromatographic separation of the sample gas into its components is
accomplished in the Analyzer in the following manner. A precise volume
of sample gas is injected into one of the unit's analytical columns. The
column contains a stationary phase (packing) that is either an active solid
(adsorption partitioning) or an inert solid support that is coated with a
liquid phase (absorption partitioning). The gas sample is moved through
the column by means of a mobile phase (carrier gas). Selective
retardation of the components of the sample takes place in the column
that causes each component to move through the column at a different
rate. This action separates the sample into its constituent gases and
vapors.

Model 500 Gas Chromatograph

A detector located at the outlet of the analytical column senses the
elution of components from the column and produces electrical outputs
proportional to the concentration of each component. Outputs from the
Analyzer detectors are amplified in the Analyzer electronics, then
transmitted to the GC Controller for further processing. See also, Section

1.5, “Theory of operation” on page 7.

Output from the GC Controller is normally displayed on a remotely
located personal computer (PC) or a printer. Connection between the GC
Controller and the PC can be accomplished via a direct serial line, the
Modbus-compatible communication interface, modem or ethernet card.

Multiple chromatograms may be displayed on the PC monitor, and
compared or contrasted with separate color schemes. This allows a stored
chromatogram to be compared/contrasted with a current or another
stored chromatogram. This could be of great assistance when changing
parameters or isolating a problem.

FUNCTIONAL DESCRIPTION JULY 2010

Model 500 Gas Chromatograph

Use of a PC for configuration and troubleshooting procedures is essential
in most instances. Basic operations can also be performed from a keypad
and liquid crystal display that are built into certain versions of the GC
Controller. The PC may be remotely connected via telephone, radio,
ethernet or satellite communications. Once installed and configured, the
Model 500 Analyzer can operate independently for long periods of time.

Description 1-5

Figure 1-1 Model 500 Analyzer Functional Block Diagram

JULY 2010 FUNCTIONAL DESCRIPTION

1-6 Description

1.4 MODES OF OPERATION

1.4.1 User Interfaces

You have at least one, and optionally two, user interfaces from which to
operate the gas chromatograph (GC) system:

PC connected to the GC and running MON2000 - The PC
connected to the GC and running MON2000 offers the greatest
amount of capability and flexibility.

Find complete user instructions for MON2000 in the program's online
HELP screens and in the program user's manual, MON2000 Software
for Gas Chromatographs User Manual (P/N 3-9000-522).

or

The GC Controller's built-in keypad and LCD - The GC
Controller's built-in keypad and LCD offer essential startup and
operation functions. They are useful in a hazardous environment or if
no PC is available.

Model 500 Gas Chromatograph

This feature is optional on all standalone models of the GC, except the
portable Compact BTU GC.

1.4.2 Capabilities

Individual gas chromatograph Controller functions that can be initiated
or controlled by the GC and its software, MON2000, are listed in the
MON2000 Software for Gas Chromatographs User Manual (P/N 3-9000-

522).

Modes of operation JULY 2010

Model 500 Gas Chromatograph

1.5 THEORY OF OPERATION

See also Section 1.6, “GLOSSARY” on page 16, for definitions
of some of the terminology used in the following explanations.

1.5.1 The Analyzer Detector

The Analyzer detector subsystem is a thermal conductivity detector that
consists of a balanced bridge network with heat-sensitive thermistors in
each leg of the bridge. Each thermistor is enclosed in a separate chamber
of the detector block. One thermistor is designated the reference element
and the other the measurement element. A schematic diagram of the
thermal conductivity detector is shown in Figure 1-2.

Description 1-7

JULY 2010 Theory of operation

1-8 Description

Model 500 Gas Chromatograph

Figure 1-2 Schematic Diagram of Analyzer Detector Bridge

In the quiescent condition (prior to injecting a sample), both legs of the
bridge are exposed to pure carrier gas. In this condition, the bridge is
balanced and the bridge output is electrically nulled. (The bridge can be
balanced by the fine and coarse adjustment potentiometers located on the
preamplifier circuit board.)

The analysis begins when a fixed volume of sample is injected into the
column by operation of the sample valve. The sample is moved through
the column by the continuous flow of carrier gas. As successive
components elute from the column, the temperature of the measurement
element changes. The temperature change unbalances the bridge and
produces an electrical output proportional to the component
concentration. The differential signal developed between the two
thermistors is amplified by the preamplifier.

The Analyzer Detector JULY 2010

Model 500 Gas Chromatograph

Figure 1-3 illustrates the change in detector electrical output during

elution of a component.

Figure 1-3 Detector output during component elution

1. Detector bridge balanced.

Description 1-9

2. First component begins to elute from column and to be sensed by the

measurement thermistor.

3. Peak concentration of first component.

4. Second component begins to elute from column and to be sensed by the

measurement thermistor.

5. Peak concentration of second component.

In addition to amplifying the differential signal developed between the
detector's two thermistors, the preamplifier also supplies drive current to
the detector bridge. The preamplifier also supplies drive current to the
detector bridge. The voltage signal is converted to a 4 to 20-milliamp
(mA) current loop for transmission to the GC Controller. The signal is
proportional to the concentration of a component detected in the gas
sample. The preamplifier provides four different gain channels as well as
compensation for baseline drift. The signals from the preamplifier are
sent to the GC Controller for computation, recording on a printer, or
viewing on a PC monitor or LCD.

JULY 2010 The Analyzer Detector

1-10 Description

1.5.2 Data Acquisition

Every second, exactly 40 equi-spaced data samples are taken for analysis
by the GC Controller (i.e., once every 25 milliseconds). Each data sample,
after having been precision-amplified, is subjected to a sixteen bit analog
to digital (A/D) conversion. The sampling frequency of 40 Hertz (Hz) was
chosen to reduce 60 Hz normal mode noise.

After each point on the chromatograph signal is sampled, the resulting
number is stored in a buffer area in the GC Controller's memory for
processing. During the analysis, only the last 256 data points are
available for processing. Because the data analysis is done as the signal
is sampled (in real-time), only a limited number of past data samples is
required to analyze any signal.

As a part of the data acquisition process, groups of incoming data samples
are averaged together before the result is stored to the Controller's
memory for processing. Non-overlapping groups of N samples are
averaged and stored, and thus reduce the effective incoming data rate to
40/N samples/second. For example, if N = 5, then a total of 40/5 or 6
(averaged) data samples are stored every second. The value for the
variable N is determined by the selection of a Peak Width parameter
(PW). The relationship is:

Model 500 Gas Chromatograph

N PW ondssec=

where PW is given in seconds. All the various details in the analysis
process are independent of the value of N. Allowable values of N are 1 to
63, which corresponds to values of PW from 1 to 63 seconds.

The variable N is known as the integration factor. This term is used
because N determines how many points are averaged or integrated to
form a single value. The integration of data upon input, before storing,
serves two purposes. First, the statistical noise on the input signal is
reduced by the square root of N. In the case of N = 4, a noise reduction of
two would be realized. Secondly, the integration factor controls the
bandwidth of the chromatograph signal. It is necessary to match the
bandwidth of the input signal to that of the analysis algorithms in the GC

Data Acquisition JULY 2010

Model 500 Gas Chromatograph

Controller. This prevents small, short duration perturbations from being
recognized as true peaks by the program. It is therefore important to
choose a Peak Width corresponding to the narrowest peak in a group
under consideration.

1.5.3 Peak Detection

For normal area or peak height concentration evaluation, the
determination of a peak's start, peak point, and end is automatic. The
manual determination of start and end points is used only for area
calculations in the Forced Integration mode. Automatic determination of
peak onset or start is initiated whenever Integrate Inhibit is turned off.
Analysis is started in a region of signal quiescence and stability, such
that the signal level and activity can be considered as baseline values. It
is important that this be the case because this assumption is made by the
GC Controller.

Description 1-11

Having initiated a peak search by turning Inhibit off, the GC Controller
performs a point by point examination of the signal slope. This is
achieved by using a digital slope detection filter which is a combination
low pass filter and differentiator. The output of this detector is
constantly compared to a system constant entered by the operator called
Slope Sensitivity. A default value of 8 is assumed if no entry is made.
Lower values make peak onset detection more sensitive, and higher
values make detection less sensitive. Higher values (20 to 100) would be
appropriate for noisy signals, e.g. high amplifier gain.

Peak termination is determined by the same application of this detector
to the signal, but in the reverse sense. Onset is defined where the
detector output exceeds the baseline constant, but termination is defined
subsequently where the detector output is less than the same baseline
constant.

Sequences of fused peaks are also automatically handled. This is done by
testing each termination point to see if the region immediately following
it satisfies the criteria of a baseline. A baseline region must have a slope
detector value less than the magnitude of the baseline constant for a
number of sequential points. When a baseline region is found, this
terminates a sequence of peaks.

JULY 2010 Peak Detection

1-12 Description

Model 500 Gas Chromatograph

A zero reference line for peak height and area determination is
established by extending a line from the point of the onset of the peak
sequence to the point of the termination. The values of these two points
are found by averaging the four integrated points just prior to the onset
point and just after the termination points, respectively. The zero
reference line will, in general, be non-horizontal, and thus compensates
for any linear drift in the system from the time the peak sequence starts
until it ends.

In a single peak situation, peak area is the area of the component peak
between the curve and the zero reference line. The peak height is the
distance from the zero reference line to the maximum point on the
component curve. The value and location of the maximum point is
determined from quadratic interpolation through the three highest points
at the peak of the discrete valued curve stored in the GC Controller.

For fused peak sequences, this interpolation technique is used both for
peaks as well as valleys (minimum points). In the latter case, lines are
dropped from the interpolated valley points to the zero reference line to
partition the fused peak areas into individual peaks. The use of
quadratic interpolation improves both area and height calculation
accuracy and eliminates the effects of variations in the integration factor
on these calculations.

For calibration, the GC Controller may average several analyses of the
calibration stream.

1.5.4 Basic Analysis Computations

Two basic analysis algorithms are included in the GC Controller. These
are:

• Area Analysis - Calculates area under component peak

• Peak Height Analysis - Measures height of component peak

Concentration Analysis by Using Response Factor

Concentration calculations require a unique response factor foreach
component in an analysis. These response factors may be manually
entered by an operator or determined automatically by the system

Basic Analysis Computations JULY 2010

Model 500 Gas Chromatograph

through calibration procedures (with a calibration gas mixture that has
known concentrations).

Response factor calculation: (using the external standard)

or

where:

ARF

HRF

n

=

=

n

Area

-------------- -

Cal

Ht

-----------

Cal

Description 1-13

n

n

n

n

ARF

HRF

Area

Ht

Cal

Area response factor for component n in area per mole percent (%).

n

Height response factor for component n.

n

Area associated with component n in calibration gas.

n

Height associated with component n in mole percent in calibration gas.

n

Amount of component n in mole percent in calibration gas.

n

Calculated response factors are stored by the GC Controller for use in the
concentration calculations, and are printed out in the configuration and
calibration reports.

Average response factor is calculated as follows:

k

RF

i

∑

i 1=

------------------

RFAVG

=

n

k

JULY 2010 Basic Analysis Computations

1-14 Description

where:

RFAVGnArea or height average response factor for component n.

Model 500 Gas Chromatograph

Rf

i

Area or height response factor for component n from the calibra­tion run.

k Number of calibration runs actually used to calculate the response

factors.

The percent deviation of new RF averages from old RF average is
calculated in the following manner:

% deviation

new

------------------------------------

RF

old

old

100×=

RF

–

RF

where the absolute value of % deviation for alarm has been previously
entered by the operator.

Concentration Calculations in Mole % without Normalization

Once response factors have been determined by the GC Controller or
entered by the operator, component concentrations are determined for
each analysis by using the following equations:

Area

n

-------------- -

CONC

=

n

ARF

n

or

Ht

n

CONC

--------------

=

n

HRF

n

where:

CONC

Area

Basic Analysis Computations JULY 2010

Concentration of component n in mole percent.

n

Area of component n in unknown sample

n

Model 500 Gas Chromatograph

Description 1-15

ARF

Response factor of component n calculated from area of calibration

n

sample. Units are area per mole percent.

Ht

n

HRF

Peak height of component n in unknown sample

Response factor of component n calculated from peak height of cal-

n

ibration sample. Units are height per mole percent.

Note that the average concentration of each component will also be
calculated when data averaging is requested.

Component concentrations may be input through analog inputs 1 - 4 or
may be fixed. If a fixed value is used, the calibration for that component
is the mole % that will be used for all analyses.

Concentration Calculations with Normalization

CONC

CONCN

n

----------------------------

∑

i 1=

k

CONC

n

100×=

i

where:

CONCN

CONC

CONC

k Number of components to be included in the normalization.

Normalized concentration of component n in percent of total gas

n

concentration.

Non-normalized concentration of component n in mole percent.

n

Non-normalized concentration (in mole percent) from each of the k

i

components to be grouped into this normalization.

JULY 2010 Basic Analysis Computations

1-16 Description

For additional information about other calculations that are
performed by the GC Controller and software, see the
MON2000 Software for Gas Chromatographs user manual (P/N
3-9000-522).

1.6 GLOSSARY

Auto Zero: Automatic zeroing of the preamplifier. May be entered into
the Controller to take place at any time during the analysis when either
the component is not eluting or the baseline is steady.

Chromatogram: A permanent record of the detector output. A
chromatograph is obtained from a PC interfaced with the detector output
through the GC Controller. A typical chromatogram displays all
component peaks, and gain changes. It may be viewed in color as it is
processed on a PC VGA display. Tick marks recorded on the
chromatogram by the GC Controller indicate where timed events take
place.

Model 500 Gas Chromatograph

Component: Any one of several different gases that may appear in a
sample mixture. For example, natural gas usually contains the following
components: nitrogen, carbon dioxide, methane, ethane, propane,
isobutane, normal butane, isopentane, normal pentane, and hexanes
plus.

Condulet: Fitting resembling a pipe or a box with a removable cover for
access to electric conduits.

CTS: Clear to send (a serial port pin assignment).

DCD: Data carrier detect; see also, RLSD (a serial port pin assignment).

DSR: Data set ready (a serial port pin assignment).

DTR: Data terminal ready (a serial port pin assignment).

GLOSSARY JULY 2010

Model 500 Gas Chromatograph

Response Factor: Correction factor for each component as determined
by the calibration. See “Concentration Analysis by Using Response

Factor” on page 12 for more information.

Retention Time: The time (in seconds) that elapses between start of
analysis (0 seconds) and the sensing of the maximum concentration of
each component by the Analyzer detector.

RI: Ring indicator (a serial port pin assignment).

RLSD: Received line signal detect (a digital simulation of carrier detect);

see also, DCD (a serial port pin assignment).

RTS: Request to send (a serial port pin assignment).

RxD, RD, or SIN: Receive data, or signal in (a serial port pin

assignment).

Description 1-17

TxD, TD, or S

assignment).

: Transmit data, or signal out (a serial port pin

OUT

JULY 2010 GLOSSARY

1-18 Description

This page is intentionally left blank.

Model 500 Gas Chromatograph

GLOSSARY JULY 2010

EQUIPMENT DESCRIPTION

This section provides descriptions of the various subsystems and
components that make up the Model 500 gas chromatograph. This
section is organized as follows:

• Sampling System

- Sampling Point Location

- Sample Volume and Flow Rate

- Sample Conditioning

- Contamination Precautions

-Valving

- Calibration Gas

•Analyzer

- Physical Description

- Chromatograph Valves

- Detector Subsystem

- Analyzer Preamplifier Unit

- Analyzer Specifications

- Utility Gas Requirements

• Controller

- Controller Hardware Configurations

- Optional Keypad and Display

- Alarm Specifications

2.1 SAMPLING SYSTEM

A well designed, properly adjusted sampling system is essential to
optimum performance of any gas chromatograph. If a good sample is not
obtained for analysis, the whole purpose of the system is compromised.

The purpose of the sample handling system is not to transfer an exact
sample of process fluid to the chromatograph. Rather, the purpose is to
transfer a representative sample of the fluid--after it has been

2-2 Equipment description

Model 500 Gas Chromatograph

conditioned--that is compatible with chromatograph sample
requirements. This statement encompasses a big difference and is very
important to remember.

The Sample Conditioning System (SCS) is located between the process
stream and the Analyzer, and is usually mounted on the lower portion of
the Analyzer stand. It serves these purposes:

• Extracts final sample from the fast loop,

• Performs final filtration,

• Performs stream switching for a multi-stream Analyzer, and

• Adjusts the final pressure, temperature, and flow control on the
selected sample flowing to the sample valve.

The following points should be considered in selecting and installing a
sampling system.

2.1.1 Sampling Point Location

Gas samples must be representative of the process stream and must be
taken from a location where stratification or separation of components
does not occur. The sampling point should be as close as feasible to the
Analyzer.

2.1.2 Sample Volume and Flow Rate

An adequate response time for sample analysis requires that sample
volumes should generally be as small as possible, and the flow rate
between the sampling point and the Analyzer should be as high as
possible, consistent with accuracy. To minimize time lag and to prevent
back diffusion, dryers and filters in the sampling line should be as small
as possible. When long sampling lines cannot be avoided, flow velocity in
the line can be increased by decreasing the downstream pressure.

Typically, pressure is reduced at the sample point with a pressure
regulating sample probe. The input pressure to the Analyzer can be
adjusted between 10 and 20 pounds per square inch, gauge (psig).
Reducing the pressure at the sample point avoids the problem of heavy
liquid dropout in the sample line during cold weather. The flow rate in

Sampling Point Location JULY 2010

Model 500 Gas Chromatograph

the sample line is set at 50 cubic centimeters (cc) per minute with the
restrictor valve at the Analyzer.

Use this general rule to approximate sample lag time caused by the
length of sample line. Sample line constructed of 1/8-inch tubing contains
approximately 1 cc of volume per foot. Therefore, with a flow rate of 50 cc
per minute, the lag time of the sample between the sample point and the
Analyzer is calculated by dividing the length of the line (in feet) by 50.
For example, the sample in a 100 foot sample line will take 2 minutes to
travel the length of the line.

2.1.3 Sample Conditioning

Sample systems should contain at least one filter to remove solid
particles from the sample stream. Most applications require fine-element
filters upstream of the Analyzer.

Equipment description 2-3

2.1.4 Contamination Precautions

Several precautions are recommended to minimize the possibility of
contaminating samples. Except in special applications, filters should be
of either the ceramic or the porous metallic type to avoid the absorption
losses characteristic of fiber or paper filters. Pressure regulators and flow
controllers containing cork or felt filters or absorbent diaphragms should
not be used. Sampling lines for noncorrosive streams should be stainless
steel tubing and must be clean and free of grease. Lines must be pressure
tight to prevent diffusion of moisture or atmospheric gases into the
sample. Pipe threads should be dressed only with Teflon tape on pipe
threads and never with pipe thread compounds (dope).

2.1.5 Valving

A block valve should be installed immediately downstream of the sample
takeoff point to permit shutdown of the system for maintenance. Block
valves should be either needle valves or cocks of the proper material and
packing, and should be rated for the process line pressure. Tight seating
of all connections is essential.

JULY 2010 Sample Conditioning

2-4 Equipment description

2.1.6 Calibration Gas

A calibration gas used for Process analysis should be blended of gases
specified as Primary Standards. Primary Standard gases are blended
using weights that are traceable to the National Institute of Standards
and Technology (N.I.S.T). The calibration gas should not have any
component that could drop out at the coldest temperature to which the
gas will be subjected. A typical C6+ blend for a temperature of zero
degrees Fahrenheit (0 °F) is listed in the following table. No dropout will
occur in this calibration gas if it is blended at a pressure below 250 psig.

Table 2-1 Contents of Example Calibration Gas

Gas Mole Percent

Nitrogen 2.5
Carbon dioxide 0.5

Model 500 Gas Chromatograph

Methane Balance
Ethane 5.0
Propane 1.0
Isobutane 0.3
N-butane 0.3
Neopentane 0.1
Isopentane 0.1
N-pentane 0.1
N-hexane 0.03

The sampling system should be carefully planned for the best chromato­graphic analyses.

Calibration Gas JULY 2010

Model 500 Gas Chromatograph

2.2 ANALYZER

2.2.1 Physical Description

The Analyzer is physically divided into two major sections (see Figure 2-

1). The upper heated section is temperature controlled and contains the

following components:

• Pneumatically actuated valves that control the flow of the sample and

carrier gases

• Detector elements

• Analytical columns

• A temperature-controlled heater block

The lower section consists of two explosion-proof housings that contain
printed-circuit assemblies for the following functions:

Equipment description 2-5

• Valve control

• Heater-block temperature control

• Detector drive

• Detector output signal preamplifier.

The Analyzer assembly, sample valves, and associated piping are
mounted in a self-supporting rack that may be placed at or near the
sample tap. Under most environmental conditions, the Analyzer
assembly requires no additional shelter.

JULY 2010 ANALYZER

2-6 Equipment description

Model 500 Gas Chromatograph

Figure 2-1 Analyzer Subsystems

Physical Description JULY 2010

Model 500 Gas Chromatograph

2.2.2 Chromatograph Valves

A chromatograph valve is shown in Figure 2-2 in exploded view. Its
pistons are pneumatically actuated in both switching directions by the
actuating assemblies located below the primary plate.

Equipment description 2-7

Figure 2-2 Chromatograph Valve

JULY 2010 Chromatograph Valves

2-8 Equipment description

Model 500 Gas Chromatograph

Primary Plate

The primary plate contains precisely machined internal passages that
enter and exit the valve at top ports, each of which is connected to the top
and/or bottom of the plate within the valve. The primary plate, which is
the only metallic element that comes in contact with the sample, is
isolated from the remainder of the valve by specially formulated
diaphragms.

GC valve should be torqued to 30 ft. lbs.

Actuating Subassemblies

Below the primary plate, pistons are operated by pneumatic pressure
applied to actuating diaphragms through ports in the base plate.

Operation

When pneumatic pressure is applied to the actuating diaphragms, the
pistons are actuated, thus forcing the sealing diaphragm against the
primary plate. This closes the passages that are connected at the bottom
of the plate. When pressure is removed, the pistons are free to move, and
flow is resumed through the passages.

2.2.3 Detector Subsystem

The operation of the Analyzer detector subsystem was previously
discussed in the "Theory of Operation" section of this manual.

Detector Subsystem JULY 2010

Model 500 Gas Chromatograph

2.2.4 Analyzer Preamplifier Unit

The electrical output from the detector is amplified by the Analyzer
preamplifier unit. The preamplifier also supplies drive current to the
detector bridge. The voltage signal is converted to a 4 to 20-milliamp
(mA) current loop for transmission to the GC Controller. The signal is
proportional to the concentration of a component detected in the gas
sample. The preamplifier provides four different gain channels and
compensates for baseline drift. The signals from the preamplifier are
then sent to the GC Controller, where they provide the basis for analysis
computations and a chromatographic trace, or chromatogram.

2.2.5 Analyzer Specifications

Power Requirements: 120 volts, alternating current (VAC), +10/­15VAC; 50 to 60 Hertz (Hz); single phase; 10 amperes (A) (maximum
during warmup) (additional 10 amps if unit has a Sample System Oven).

Equipment description 2-9

Ambient Temperature Range: -18 degrees Celsius ( C) to +55 C (0 F to
+130 F)

Humidity: 0 to 95 percent relative humidity, noncondensing

Vibration: Designed for mounting on process piping or other field

structures subject to normal process vibrations

National Electrical Code (NEC) Area Classification: Suitable for
NEC Class 1, Division 1, Groups B, C, and D

Rack Size:

• Height: 58 inches (147.3 centimeters [cm])

• Width: 18 inches (45.7 cm) maximum

• Depth: 18 inches (45.7 cm)

Weight: Approximately 125 pounds (56.8 kilograms [kg]), including
mounting hardware.

JULY 2010 Analyzer Preamplifier Unit

2-10 Equipment description

Sample Requirements:

• Fluid Phase - Vapor

• Pressure - 15 to 30 psig, regulated to ±10 percent

• Flow Rate - 50 cc/min, typical

Analyzer Output Signal: Four different gain channels to provide a 4 to
20 mA signal to the Controller.

Transient Over Voltages Category: Installation Category (Over
Voltage Category II)

Cleaning requirements: Restricted to the 6-port valve (refer to “Valve

Cleaning” on page 5-22).

2.2.6 Utility Gas Requirements

Model 500 Gas Chromatograph

Carrier Gas: Typically zero grade helium (99.995% pure, with less than
5 ppm water, and less than 0.5 ppm hydrocarbons).

Valve Actuation Gas: Typically zero grade, 99.995% pure helium at 115
psig. Consumption is 100cc per analysis cycle. Clean, dry air also may be
used for valve actuation. Carrier Gas and Valve Actuation Gas are
normally supplied from a common cylinder, since overall gas consumption
is minimal.

2.3 CONTROLLER

The Model 500 Controller is a microprocessor-based device that provides
the Model 500 Analyzer with highly accurate timing, precision
calculations, pertinent report generation, and an interface with other
devices. The Controller provides both analog outputs and a direct digital
link with output devices through RS-232C, RS-422, or RS-485 ports.
Volatile portions of the program are protected by a lithium battery
backup if power is lost or turned off at the unit.

Utility Gas Requirements JULY 2010

Model 500 Gas Chromatograph

The Controller can be packaged for side-by-side use with the Model 500
Analyzer in a hazardous area, or for remote use in a safe area in a 19-inch
rack mounting. Also, a retrofit kit is available to replace the older model
GC Controller (Model 2251) used with the Model 500 Analyzer. The
retrofit kit is suitable for 12-inch rack mounting.

The Model 500 Controller can be linked directly to a PC by serial
connection or by a telecommunication link that uses Modbus protocol.
This provides the preferred method for operating the GC System.
Limited control of the GC System is also possible through a built-in
keypad and display, which are optional components of the explosion­proof, hazardous environment GC Controller package. The local
alphanumeric keypad and display allow for maintenance and minor
adjustments in a hazardous environment.

Equipment description 2-11

SERIOUS PERSONAL INJURY OR DEATH POSSIBLE

Do not operate a PC or printer in a hazardous environment.

Failure to observe all safety precautions could result in serious injury
or death.

The 19-inch rack mounted, 12-inch rack retrofit kit, and the explosion­proof NEMA 4X, Groups B, C, and D, Controllers all operate identically.

JULY 2010 CONTROLLER

2-12 Equipment description

2.3.1 Controller Hardware Configurations

The Controller may be provided for hazardous area mounting, 19-inch
rack mounting, or used in a 12-inch rack retrofit kit. See Figure 2-3
through Figure 2-5. The unit consists of an STD-bus based computer and
related boards, including boards for terminating field wiring. The
enclosure for hazardous areas qualifies as flameproof (explosion-proof
NEMA 4X, Groups B, C, and D). Connections to the enclosure are
through one 2-inch (50mm) hole (reduced to 3/4 inch with bushing) and
two 1-inch (25 mm) conduit fittings located in the bottom. These accept
matching conduit or cable entries. Field connections are made through
explosion-proof conduit or flameproof glands.

Model 500 Gas Chromatograph

Figure 2-3 GC Controller, Explosion-Proof Version

Controller Hardware Configurations JULY 2010

Model 500 Gas Chromatograph

Equipment description 2-13

Figure 2-4 GC Controller, 19-inch Rack Mounted Version

JULY 2010 Controller Hardware Configurations

2-14 Equipment description

Model 500 Gas Chromatograph

Figure 2-5 Model 2251 Retrofit Kit (12-inch rack) for the GC Controller

For operating a printer in a nonhazardous area at the GC site, a DB-25
parallel port is available on the GC's Terminal Board for field wiring.

For connecting a PC to the GC at the GC site (for setup, operation, or
maintenance in a nonhazardous area), a DB-9 serial port connector is
available on the Controller's front panel.

Controller Hardware Configurations JULY 2010

Model 500 Gas Chromatograph

The STD-Bus Card Cage inside the GC Controller is equipped with two
cards. Card slots are preassigned so that cables can be consistently
routed. However, the COM4A board and the modem board (and Ethernet
card when using a 16-bit CPU board) can be piggy-backed in any order on
the CPU board. If a Radicom modem is used, it must be the top board in
the card cage assembly.

An optional stream switching assembly (with either AC or DC solenoids)
can be controlled by the GC Controller, allowing for switching up to 12
streams.

Analog Inputs and Outputs

The GC Controller can accommodate eight fully differential analog 4 to 20
mA input signals. Four of the analog inputs are used by the associated
Analyzer, and they are filtered with transient protection. The additional
four input ports provide the ability to accept signals from other
Analyzers, so that the analytical report of the chromatograph can include
other information on the gas stream, such as water or sulphur content.
Transient protection and shield terminations are available for these
inputs.

Equipment description 2-15

There is capability for a maximum of ten analog outputs. Two analog
outputs are available as standard components of the Controller; the other
eight analog outputs are optional. All ten analog outputs are current
type: 4-20 mA, not isolated. Also, all ten analog outputs can be calibrated
by the MON2000 software.

Digital Inputs and Outputs

The Controller has the capability of sixteen digital inputs used as follows:

5 - to read a Modbus address, as defined by DIP switch positions.

2 - to indicate presence and type of front panel as defined by switch
positions

1 - Spare

1 - temperature sensor input to shut off LCD backlight

1 - GC alarm, optically isolated, with transient protection

JULY 2010 Controller Hardware Configurations

2-16 Equipment description

Model 500 Gas Chromatograph

5 - stream flow alarms, optically isolated, with transient protection

1 - photocell detector, front panel backlight (night on, day off)

The Controller has the capability of 22 digital outputs used as follows:

6 - Analyzer control

8 - driver outputs for DC air solenoids (stream switching, 12 total
streams)

5 - alarms, optically isolated, with transient protection

3 - front panel indicators (green, yellow, red)

The digital transient-protected discrete outputs can furnish up to 50 mA.
If more current is required (up to 0.5A), a special transient protection
plug-in module should be installed (see Appendix C, this manual, for
transient protection module details).

Communications

There are 3 to 8 communication ports externally available, depending on
options package selected. The communications ports can use either RS­232, RS-422, or RS-485 protocol, which, for the LX-800 CPU board, can be
set via MON20/20, and for the 6117 CPU board, must be set by Data
Interface Chips resident on the board.

The communications ports are configured at the factory, as specified by
the customer's communications requirements. The Modbus switch
positions are also normally set at the factory as specified by the customer.
If any changes need to be made in the field, refer to the drawings in the
rear of this manual.

Controller Hardware Configurations JULY 2010

Model 500 Gas Chromatograph

Driver Outputs

The Controller has eight stream switch outputs, 120 mA continuous
current, which can be used to control optional AC or DC solenoid switch
boards. This increases stream switch capability from the standard
capability of four streams and 1 CAL to a maximum capability of twelve
streams.

The optional stream switching assembly (AC or DC solenoid
systems) has provisions for eight stream routes, but adding this
option has the net effect of adding only seven more stream routes
to the standard stream capacity of five (thus giving a total stream
capacity of twelve). The reason is, one of the Analyzer's standard
five stream routes becomes dedicated to the optional stream switch
assembly when the optional stream switch assembly is installed.

Equipment description 2-17

General Controller Specifications

Power requirements (without current outputs): 63.25VA typical for
basic instrument

Voltage options:

• 115 VAC ±15 percent, 50 to 60 Hz @ 0.33 A

• 230 VAC ± 15 percent, 50 to 60 Hz @ 0.275 A

Temperature:

• Operating range: -18 C to 55 C (0 F to 131 F)

• Storage range: -40 C to 85 C (-40 F to 185 F)

Humidity: 0 to 95 percent relative humidity, noncondensing

JULY 2010 Controller Hardware Configurations

2-18 Equipment description

Model 500 Gas Chromatograph

Explosion-proof NEMA 4X, Groups B, C, and D, enclosure
dimensions:

• Height:13 inches

• Width:14 inches

• Depth: 14 inches

Rack mounted dimensions (standard 19-inch):

• Height:8.75 inches

• Width: 19 inches

• Depth: 8.5 inches

Retrofit kit enclosure dimensions (12-inch rack, "panel mount"):

• Height:8.5 inches

• Width:11 inches

• Depth:11 inches

Weight: Approximately 74 pounds for Explosion-Proof NEMA 4X,
Groups B, C, and D, version (not including stand)

Electrical/Mechanical Safety and Integrity - Certifications and
Classifications

Both the Analyzer and the GC Controller, when housed inside explosion­proof enclosures, meet these certifications and classifications for
electrical and/or mechanical safety and integrity:

National Electrical Manufacturers Association (NEMA) 7 for National
Electrical Code (NEC) Class I, Division 1, Groups B, C, and D areas.
Meets Underwriters Laboratories Inc. (UL) 1203, "Explosion-Proof
and Dust-Proof Electrical Equipment of use in hazardous (Classified)
locations" for NEC Class I, Division 1, Groups B, C, and D, and
Canadian Standards Association (C.S.A.) 22.2 No. O-M1962, Part II
and C.S.A. 22.2 No. 30-M1986 for NEC Class I, Division 1, Groups B,
C, and D.

Controller Hardware Configurations JULY 2010

Model 500 Gas Chromatograph

EEx d IIB T6 - Meets CENELEC EN 50 014, and EN 50 018,
"Electrical Apparatus for Potentially Explosive Atmospheres...", Parts
1 and 5, as flameproof for Group II, Subdivision B, Temperature Class
T6.

The GC Controller, when housed inside explosion-proof enclosure, meets
these certifications and classifications for electrical and/or mechanical
safety and integrity:

NEMA 4X - Meets NEMA 250, "Enclosures for Electrical Equipment
(1000 volts maximum)", for type 4X, Canadian Electrical Code, Part
II, Rule 2-400 1 d, and C.S.A. C22.2 No. 94-1967 as C.S.A. enclosure 4,
and International Electrotechnical Commission (IEC) 144, "Degrees of
protection of enclosures of Switchgear...", for IP 65.

Both the Analyzer, when housed inside explosion-proof enclosure, and the
GC Controller, when housed inside (a) the explosion-proof enclosure, (b)
the rack mount enclosure, or the retrofit enclosure, meet the Federal
Communications Commission (FCC) Part 15, Subparts A and B
classification for control against excessive radio frequency emissions.

Equipment description 2-19

GC Controller Circuit Board List

The GC Controller circuit boards are inserted or attached to an STD-bus
card cage assembly. The Controller has two boards inserted into the card
cage, and two of the boards are attached to the card cage outside.

The 6117 CPU board has three optional piggy-back boards that can be
attached to it via the PC 104 bus:

• Modem

• COM4A serial ports 5, 6, 7, and 8

• Ethernet

JULY 2010 Controller Hardware Configurations

2-20 Equipment description

Model 500 Gas Chromatograph

There are two optional piggy-back boards that can be attached to the LX­800 CPU board via the PC 104 bus:

•Modem

• COM4A serial ports 5, 6, 7, and 8

The LX-800's onboard Ethernet port can be used instead of the
optional Ethernet board, unless the LX-800 is installed with
application revision 3.99 or earlier (16 bit BOS), in which case, the
Ethernet board must be used.

onboard ethernet port

Controller Hardware Configurations JULY 2010

Model 500 Gas Chromatograph

The inserted circuit boards of the GC Controller perform these functions:

Table 2-2 Functions of Inserted Circuit Boards, GC Controller Card Cage Assembly

Equipment description 2-21

Subsystems

32-bit CPU
microprocessor
board

or

16-bit CPU
microprocessor
board

COM4A Board
(CPU Daughter
board)

Modem (CPU
Daughter board)

Analog I/O board

[requires
MON2000
software, version

2.3 or later]

Handle Label
or Part Number

LX800

MCM/LPM-6117

Analog* Control of eight analog inputs

Function(s)

Microprocessor; control of
parallel printer port; control
of COM1, COM2, COM3, and
COM4 communication ports;
system memory; RS-422
serial protocol; three timers,
digital I/O, and
CompactFlash. Additional
memory for higher capacity
data archives.

Control of COM5 - COM8 BE-20767

telephone modem N/A

(4 for user applications and 4
for Analyzer-Controller inter­connect) and two, six, or ten
analog outputs

See drawing
number...

DE-20782

BE-18044

Ethernat Card
(16-bit CPU
daughter board)

PCM-NE 2000 Flexible, high-performance

networking capability; broad
spectrum of software support.

N/A

There are two circuit boards attached to the outside of the card cage:

• The System Interface and Driver board, and

• The GC Controller's Terminal Board for Field Wiring.

The GC Controller's Terminal Board for Field Wiring provides
termination connections for these items:

• Communication ports (COM1, COM2, COM3, COM4, COM5, COM6,

COM7, and COM8),

JULY 2010 Controller Hardware Configurations

2-22 Equipment description

Model 500 Gas Chromatograph

• Analog inputs and outputs,

• Digital inputs and outputs,

• Controller-Analyzer interconnections,

• Parallel printer port, and

• Optional stream switching assemblies.

See drawing DE-20782 for an illustration of the GC Controller's
Terminal Board for Field Wiring.

The GC Controller's Terminal Board for Field Wiring also has sockets for
transient protection modules, and a 250 VAC, 2A fuse (5 x 20 mm) that
protects all of the boards from transient surges.

See Appendix C and drawing CE-18115 for a list of transient
suppression modules that are installed for various configurations of
the GC Controller and its communication, analog output, and
stream-switching options.

The System Interface and Driver board provides these functions:

• Drivers for switching the eight optional valve solenoids,

• Location for 8-position DIP switch to set the Modbus address,

• Opto-isolation circuits for the discrete inputs and outputs,

• Switching power supply and temperature shutdown circuit for the
LCD display,

• RS-232 to RS-422 conversion for the LCD display, and

• Voltage-to-current conversion for the analog outputs.

Controller Hardware Configurations JULY 2010

Model 500 Gas Chromatograph

• Jumper for selecting driving voltage source for the 4-20 mA circuit.

See drawing CE-18118 for an illustration of the System Interface
and Driver board.

Also see Figure 2-6, which illustrates, through a block diagram, the
function and placement of the GC Controller circuit boards.

Equipment description 2-23

JULY 2010 Controller Hardware Configurations

2-24 Equipment description

Model 500 Gas Chromatograph

Figure 2-6 Block Diagram of the GC Controller Circuit Boards

Controller Hardware Configurations JULY 2010

Model 500 Gas Chromatograph

2.3.2 Optional Keypad and Display

A keypad and liquid crystal display (LCD), optionally built into the
enclosure's front panel, are available for the explosion-proof and rack
mount versions of the GC Controller. (See Figure 2-5 for an illustration of
the explosion-proof Controller with optional keypad and LCD.) The built­in keypad and LCD are especially useful for the explosion-proof version.
They permit onsite display, control, and data entry at a GC Controller
that is situated in a hazardous environment. Note, however, that the
control capabilities offered through the built-in keypad and LCD are more
limited than those available through a PC connected to the GC
Controller.

For details on using the Controller's built-in keypad and LCD, see

“Operation from Local Keypad and Display” on page 4-1.

Equipment description 2-25

Keypad

The front panel keypad is an 18-Key data/function entry device arranged
so that the ALT key causes the lower key markings to be displayed/
entered. The designations marked on the top of the keys will be
displayed/entered when the ALT key is not pressed.

Display

The Controller display, measuring 5.5 x 2 inches, is capable of 8 lines by
41 characters. It is certified for use with a explosion-proof NEMA 4X,
Groups B, C, and D, enclosure. The display is capable of producing the
complete alphabet and numbers from the keypad. The video display on
the Controller may show a truncated (or curtailed) version of the displays
available at the PC. Although the keypad/display located at the
Controller site can do many of the functions that the PC software can do
remotely, any extensive operations are more conveniently performed
through MON2000 on the larger screen and keypad of a PC. A few
adjustments will be more conveniently accomplished at the Controller
site.

JULY 2010 Optional Keypad and Display

2-26 Equipment description

2.3.3 Alarm Specifications

The GC Controller has the capacity for 36 alarms. There are also
operator defined alarms. Some of the alarms are active only if the
configuration of the Controller requires the function that is associated
with those alarms. Active alarms are shown in the ALARMS menu.

Status Indicators

Three colored LED status indicators are located at the side of the display
on the front panel. The indicators are arranged from yellow, green, and
red. When illuminated, the LED status indicators signify the following:

• Yellow LED: When illuminated, the Yellow LED indicates that an
out-of-tolerance value or an alarm condition was entered into the
Controller memory for printout with the analysis. The Controller
memory retains the alarm for printout until the operator clears the
alarm(s). This indicator is partially application controlled and may be
set at different out-of-tolerance levels with different applications.

Model 500 Gas Chromatograph

• Green LED: When illuminated, the Green LED indicates that the
Controller is operating. If the green LED is illuminated and the Model
500 does not accept changes, a password lockout may have been
entered. If a password has been entered, the password must be re­entered before the Model 500 program can be changed.

• Red LED: When illuminated, the Red LED indicates an out-of­tolerance value or an alarm condition in the RUN mode that requires
operator action. Alarm contacts are closed under these conditions.
The Red LED is automatically turned off and contacts opened by the
Controller at the start of the next analysis.

Alarm Specifications JULY 2010

Model 500 Gas Chromatograph

This page is intentionally left blank.

Equipment description 2-27

JULY 2010 Alarm Specifications

2-28 Equipment description

Model 500 Gas Chromatograph

Alarm Specifications JULY 2010

INSTALLATION AND SETUP

Because the Model 500 Gas Chromatograph system is available in
different configurations, not all of the instructions in this section
may apply. In most cases, however, to install and set up a Model
500 Gas Chromatograph system, it is recommended that you follow
the instructions in nearly the same order as presented in this
manual. (Also see Table 3-1 for a summary of installation and setup
steps.)

This section provides instructions for installing and setting up the Model
500 Gas Chromatograph system. This section is organized as follows:

• Precautions and Warnings

- Hazardous Environments

- Power Source Wiring

- Signal Wiring

- Electrical and Signal Ground

- Electrical Conduit

- Sample Systems Requirements

• Preparation

-Introduction

- Site Selection

- Unpacking the Unit

- Necessary Tools and Components

- Optional Tools and Components

• Installing the Analyzer

- Point-to-Point Wiring Guide, Analyzer-Controller

- Analyzer AC-Power Wiring

- Sample and Gas Lines

3-2 Installation and Setup

Model 500 Gas Chromatograph

• Installing the GC Controller

- Modbus Slave Address (COM ID) Setup

- Controller-Analyzer Wiring

- Controller-PC Wiring (Serial Connections)

- CPU and COM4A Serial Communications Setups

- Controller-Printer Wiring

- Discrete (Digital) I/O Wiring

- Analog I/O Wiring

- Controller AC-Power Wiring

•Analyzer Leak Checks and Purging for First Calibration

-Analyzer Leak Checks

- Purging Carrier Gas Lines

- Purging Calibration Gas Lines

• System Start-up

Summary of Installation and Setup Steps

1. Observe Precautions and Warnings (See “Precautions and Warnings”

on page 3-3)

2. Plan Site Location (See “Preparation” on page 3-12)

3. Obtain Supplies and Tools (See “Necessary Tools and Components” on

page 3-15)

4. Install Analyzer Wiring (See “Point-to-point Wiring Guide, Analyzer-

Controller” on page 3-18)

5. Install Analyzer Sample & Gas Lines (See “Sample and Gas Lines” on

page 3-27)

6. Install GC Controller Wiring (See “Installing the GC Controller” on

page 3-30)

7. Perform Leak Checks (See “Analyzer Leak Checks” on page 3-78)

8. Purge Carrier Gas Lines (See “Purging Carrier Gas Lines” on page 3-

80)

9. Purge Calibration Lines (See “Purging Calibration Gas Lines” on

page 3-83)

JULY 2010

Model 500 Gas Chromatograph

10.Start Up GC System (See “System Start-Up” on page 3-85)

3.1 PRECAUTIONS AND WARNINGS

The Analyzer and GC Controller, when housed inside explosion­proof enclosures, meet the certifications and classifications
identified in “Electrical/Mechanical Safety and Integrity -

Certifications and Classifications” on page 2-18. Emerson does

not, however, accept any responsibility for installations of these,
or any attached equipment, in which the installation or operation
thereof has been performed in a manner that is negligent and/or
non-compliant with applicable safety requirements.

Installation and Setup 3-3

EQUIPMENT DAMAGE OR PERSONAL INJURY

The responsible body shall operate the equipment as designed and
specified by the manufacturer.

Failure to do so may cause personal injury or damage to the
equipment.

JULY 2010 Precautions and Warnings

3-4 Installation and Setup

3.1.1 Hazardous Environments

Observe Precautions and

1

Warnings

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Follow these precautions if installing or operating the Model 500
Analyzer and the GC Controller instrumentation in a hazardous

area:

1. Install and operate only the explosion-proof version of the GC
Controller in a hazardous area.

Model 500 Gas Chromatograph

2. Do not operate in a hazardous area any printer or personal computer
(PC) that is connected to the GC Controller. To interface with a GC
Controller in a hazardous area, use the Controller's keypad and liquid
crystal display (LCD) that are built into the explosion-proof housing
as options. Or, alternatively, use a PC that is located in a
nonhazardous area and remotely connected to the GC Controller.

3. Ensure that field connections to the Analyzer and the GC Controller
are made through explosion-proof conduit or flameproof glands.

EQUIPMENT DAMAGE OR PERSONAL INJURY

Observe ALL applicable regulations when installing explosion-proof
GC units.

Failure to observe all regulations when installing explosion-proof GC
units may result in noncompliance, equipment damage or personal
injury.

Hazardous Environments JULY 2010

Model 500 Gas Chromatograph

The explosion-proof GC Controller and Analyzer housings are certified for
use in locations where fire and explosion hazards may exist, specifically,
areas that are classified by the National Electronics Code (NEC) as Class
I, Division 1, Groups B, C, and D. However, other regulations apply. For
example, all interconnecting runs of cable through conduit must be sealed
at least 18 inches beyond the conduit's point of entry into certified
explosion-proof housing. Consult your company's policies and procedures
and other applicable requirements documents to determine appropriate
wiring and installation practices.

3.1.2 Power Source Wiring

1
2

3

Installation and Setup 3-5

Observe Precautions and
Warnings

Plan Site Location

Obtain Supplies and Tools

Install Analyzer Wiring

4

Follow these precautions when installing AC power source
wiring to the Model 500 Analyzer and the GC Controller instru­mentation:

1. All wiring must conform to the National Electric Code, local state or

other jurisdiction, and company standards and practices.

2. Provide single-phase, three-wire, AC power at 115 or 230 volts AC, 50-

60 Hz.

3. A switch or circuit breaker shall be included in the building

installation in a safe area.

(a) The switch or circuit breaker is marked as the power disconnect

device.

(b) For Rack mount units, the power disconnect switch shall be in

close proximity to the equipment and easily accessible to the
operator.

4. Provide 20 ampere circuit breaker protection so that the major

components of the Model 500 Analyzer system–the Analyzer, the GC

JULY 2010 Power Source Wiring

3-6 Installation and Setup

Controller, and any optionally installed sample oven or stream
switching devices--are all protected by one circuit breaker.

5. Use multi-stranded copper conductor wire according to the following
recommendations:

(a) For power feed distances up to 250 feet (76 meters), use wire size

American Wire Gauge (AWG) 14 (18 Metric Wire Gauge, stranded).

(b) For power feed distances 250 feet to 500 feet (76 meters to 152

meters), use wire size AWG 12 (25 Metric Wire Gauge, stranded).

(c) For power feed distances 500 feet to 1000 feet (152 meters to 305

meters), use wire size AWG 10 (30 Metric Wire Gauge, stranded).

3.1.3 Signal Wiring

Observe Precautions and Warnings

1

Plan Site Location

2

Model 500 Gas Chromatograph

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Follow these general precautions for field wiring digital and
analog input/output (I/O) lines:

1. Metal conduit must be used for all process signal wiring.

2. Metal conduit used for process signal wiring must be grounded at
conduit support points (grounding the conduit at multiple points helps
prevent induction of magnetic loops between the conduit and cable
shielding).

3. Use suitable lubrication for wire pulls in conduit to prevent wire
stress.

4. All process signal wiring should be a single, continuous length
between field devices and the GC Controller. If, however, length or
conduit runs require that multiple wiring pulls be made, the
individual conductors must be interconnected with suitable terminal
blocks.

Signal Wiring JULY 2010

Model 500 Gas Chromatograph

5. Use separate conduits for AC voltage and DC voltage circuits (see

Figure 3-1).

6. Do not place digital or analog I/O lines in same conduit as A-C power

circuits (see Figure 3-1).

7. Use only shielded cable for digital I/O line connections.

(a) Ground the shield at only one end.
(b) Shield-drain wires must not be more than two AWG sizes smaller

than the conductors for the cable.

Installation and Setup 3-7

Figure 3-1. Seperate Conduit Entries

JULY 2010 Signal Wiring

3-8 Installation and Setup

Model 500 Gas Chromatograph

8. When inductive loads (relay coils) are driven by digital output lines,
the inductive transients must be diode clamped directly at the coil.

9. Any auxiliary equipment wired to the GC Controller must have its
signal common isolated from earth/chassis ground.

Applicable to the digital and analog I/O lines connecting to the GC
Controller, including the Analyzer-Controller Interconnect lines: Any
loop of extra cable left for service purposes inside the GC Controller
explosion-proof housing must not be placed near the conduit entry
for AC power.

If the above precaution is not followed, the data and control signals
to and from the GC Controller can be adversely affected.

3.1.4 Electrical and Signal Ground

Observe Precautions and

1

Warnings

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Follow these general precautions for grounding electrical and
signal lines:

1. For shielded signal conducting cables, shield-drain wires must not be
more than two AWG sizes smaller than the conductors for the cable.
Shielding is grounded at only one end.

2. Metal conduit used for process signal wiring must be grounded at
conduit support points (Grounding the conduit at multiple points
helps prevent induction of magnetic loops between the conduit and
cable shielding).

3. A clamp type ground lug (color green) is located on the inside bottom
front of the GC Controller's case. Chassis ground conductors (color

Electrical and Signal Ground JULY 2010

Model 500 Gas Chromatograph

code green) inside the Controller's enclosure should be stranded,
insulated copper wire. These device chassis ground conductors should
all be connected to the clamp type ground lug.

4. A clamp type ground lug is located on the outside of the GC

Controller's case at the rear of the lower right (facing the operator
panel) casting rib. This ground point should be connected to a copper
ground rod as described next.

5. A single-point ground (the outside case ground lug) must be connected

to a copper-clad, 10-foot long, 0.75" diameter steel rod, which is
buried, full-length, vertically into the soil as close to the equipment as
is practical. (Grounding rod not provided by Rosemount Customer

Care.)

6. Resistance between the copper-clad steel ground rod and the earth

ground must not exceed 25 Ohms.

7. The equipment-grounding conductors used between the GC Controller

and the copper-clad steel ground rod must be sized according to the
following specifications:

Installation and Setup 3-9

-length, 15 feet or less-

(4.6 meters) AWG 8, stranded, insulated copper wire

-length, 15 to 30 feet-

(4.6 to 9.1 meters) AWG 6, stranded, insulated copper wire

-length, 30 to 100 feet-

(9.1 to 30.5 meters) AWG 4, stranded, insulated copper wire

8. All inter-enclosure equipment-grounding conductors must be

protected by metal conduit.

9. External equipment, such as data printers, that are connected to the

GC Controller should be powered via isolation transformers to
minimize the ground loops caused by the internally shared safety and
chassis grounds.

JULY 2010 Electrical and Signal Ground

3-10 Installation and Setup

3.1.5 Electrical Conduit

Observe Precautions and

1

Warnings

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Model 500 Gas Chromatograph

Follow these general precautions for conduit installation

:

1. Conduit cutoffs must be square. Cutoffs must be made by a cold
cutting tool, hacksaw, or by some other approved means that does not
deform the conduit ends or leave sharp edges.

2. All conduit fitting threads, including factory-cut threads, must be
coated with a metal-bearing conducting grease, such as Crouse-Hinds
STL or equivalent, prior to assembly.

3. Temporarily cap the ends of all conduit run runs immediately after
installation to prevent accumulation of water, dirt, or other
contaminants. If necessary, swab out conduits prior to installing the
conductors.

4. Install drain fittings at the lowest point in the conduit run; install
seals at the point of entry to the GC Controller's explosion-proof
housing to prevent vapor passage and accumulation of moisture.

5. Use liquid-tight conduit fittings, such as Myers® Scru-tite® or
similar, for conduit which is exposed to moisture.

When conduit is installed in hazardous areas (e.g., areas classified as
NEC Class I, Division 1, Groups B, C, and D), follow these general
precautions for conduit installation:

1. All conduit runs must have an explosion-proof sealing (potting) fitting
located within 18 inches (45.5 centimeters) distance from the conduit
entrance to explosion-proof housings.

2. The conduit installation must be vapor tight, with threaded hub
fittings, sealed conduit joints and gaskets on covers, or other approved
vapor-tight conduit fittings.

Electrical Conduit JULY 2010

Model 500 Gas Chromatograph

EQUIPMENT DAMAGE OR PERSONAL INJURY

Consult your company's policies and procedures and other
applicable requirements documents to determine wiring and
installation practices that are appropriate for hazardous areas.

Failure to do so may cause personal injury or damage to equipment.

3.1.6 Sample Systems Requirements

Observe Precautions and

1

Warnings

Installation and Setup 3-11

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Observe the following guidelines for installing GC sample
systems:

Sample Line Length: If possible, avoid long sample lines. In case of a

long sample line, flow velocity can be increased by decreasing
downstream pressure and using by-pass flow via a speed loop.

Sample Line Tubing Material:

• Use stainless steel tubing for noncorrosive streams.

• Ensure tubing is clean and free of grease.

Dryers and Filters in Sample Line:

• Use small sizes to minimize time lag and prevent back diffusion.

JULY 2010 Sample Systems Requirements

3-12 Installation and Setup

Model 500 Gas Chromatograph

• Install a minimum of one filter to remove solid particles. Most
applications require fine-element filters upstream of the Analyzer.

• Do use ceramic or porous metallic type filters. Do not use cork or felt
filters.

Pressure Regulators and Flow Controllers in Sample Line: Do not
use types containing cork or felt filters, or absorbent diaphragms.

Pipe Threads, Dressing: Do use Teflon tape. Do not use pipe thread
compounds (dope).

Valving:

• Install a block valve downstream of sample takeoff point for
maintenance and shutdown.

• Block valve should be needle valve or cock valve type, of proper
material and packing, and rated for process line pressure.

3.2 PREPARATION

3.2.1 Introduction

Your Model 500 Analyzer was started and checked out before it left the
factory. Program parameters were installed in the system and
documented in the "PC Config Report" furnished with your Model 500
Analyzer.

Preparation JULY 2010

Model 500 Gas Chromatograph

3.2.2 Site Selection

Observe Precautions and

1

Warnings

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Installation and Setup 3-13

Follow these guidelines for site selection

:

1. Provide adequate access space for performing maintenance and

adjustments.

(a) Allow a minimum of 16 inches (41 cm) in front for enclosure

opening and access.

(b) Allow a minimum of 15 inches (38 cm) at the rear and left side for

case removal.

(c) If possible, mount the Analyzer components in a vertical stack

configuration; it provides the greatest operator convenience.

2. Install the Analyzer as close as possible to the sample stream.

3. Install the GC Controller no further than 2000 feet (610 meters) away

from the Analyzer.

(a) In a hazardous environment, you can install the explosion-proof

version of the GC Controller near the Analyzer, on either a 19-inch
or 12-inch rack.

(b) Observe the same recommendations for minimum clearance: 16

inches (41 cm) in front enclosure opening and access, and 15 inches
(38 cm) at the rear and left side for case removal.

(c) Refer to drawing CE-23878 in the Analyzer drawings addendum of

this manual.

4. Ensure that exposure to radio frequency (RF) interference is minimal.

JULY 2010 Site Selection

3-14 Installation and Setup

3.2.3 Unpacking the Unit

Observe the following checklist for unpacking the unit and
inspecting for damage:

1. Unpack the equipment:

(a) Model 500 series Analyzer
(b) GC Controller

Observe Precautions and

1

Warnings

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Model 500 Gas Chromatograph

2. Ensure that all documentation and software are included:

(a) This manual, the Model 500 Gas Chromatographs Hardware

Reference Manual, P/N 3-9000-537.

(b) The software manual, MON2000 Software for Gas

Chromatographs User Manual, P/N 3-9000-522.

(c) CD(s) with the MON2000 software program and GC Applications.

Installation and startup of the Model 500 Analyzer should proceed only if
all required materials are on hand and free from obvious defects. If any
parts or assemblies appear to have been damaged in shipment, first file a
claim with the carrier. Next, complete a full report of the nature and
extent of the damage and forward the report immediately to Rosemount
Customer Care for further instructions. Include complete model
number information. Disposition instructions will be returned
immediately by Rosemount Customer Care. Refer to the Customer
Repair Report in the back of this manual.

Unpacking the Unit JULY 2010

Model 500 Gas Chromatograph

3.2.4 Necessary Tools and Components

Observe Precautions and

1

Warnings

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Observe the following checklist of tools and components that you
will need for installing the Analyzer and GC Controller:

1. Chromatographic grade carrier gas: zero grade helium or nitrogen

(99.995% pure, with less than 5 ppm water, and less than 0.5 ppm
hydrocarbons).

Installation and Setup 3-15

2. High pressure dual-stage regulator for the carrier gas cylinder, high

side up to 3000 pounds per square inch, gauge (psig), low side capable
of controlling pressure up to 150 psig.

3. Calibration standard gas with correct number of components and

concentrations (see Section 2.1.6, “Calibration Gas” on page 4).

4. Dual-stage regulator for the calibration gas cylinder, low pressure side

capable of controlling pressure up to 30 psig.

5. Sample probe (fixture for procuring the stream, or sample gas for

chromatographic analysis).

6. 1/8-inch stainless steel (SS) tubing for connecting calibration standard

to analyzer, 1/4-inch SS tubing for connecting helium carrier to the
analyzer, 1/8-inch SS tubing for connecting stream gas to the
analyzer.

7. Miscellaneous Swagelok tube fittings, tubing benders and tubing

cutter.

8. 14 American Wire Gauge (AWG) (18 Metric Wire Gauge) or larger

electrical wiring and conduit to provide 115 or 230 volts AC, single
phase, 50 to 60 Hertz (Hz), from an appropriate circuit breaker and
power disconnect switch. (See previous guidelines in Section 3.1.2,

“Power Source Wiring” on page 5.)

JULY 2010 Necessary Tools and Components

3-16 Installation and Setup

9. Liquid leak detector (SNOOP® or equivalent).

10.Digital volt-ohm meter with probe-type leads.

11.A flow measuring device such as Alltech Digital Flow Check™
Flowmeter.

3.2.5 Optional Tools and Components

Observe Precautions and

1

Warnings

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Observe the following checklist of tools and components you may
need for installing and using the GC System:

Model 500 Gas Chromatograph

1. For operation in a nonhazardous area only: Printer and printer paper.

2. For operation in a nonhazardous area only: An IBM-compatible PC
and a "straight-through" serial cable connection between the external
DB-9 (female) serial ports of the GC Controller and a serial port of the
PC. (For details, see Section 3.4.3, “Controller PC Wiring (Serial

Connections)” on page 37.).

SERIOUS PERSONAL INJURY OR DEATH POSSIBLE

Do not operate a PC or printer in a hazardous environment.

Failure to observe all safety precautions could result in serious injury
or death.

Optional Tools and Components JULY 2010

Model 500 Gas Chromatograph

If you are working in a hazardous area and need to perform routine
operations, use the optional keypad and LCD that are built into the
explosion-proof GC Controller. To make more significant changes,
however, use a remotely connected PC installed with MON2000. See
the MON2000 Software for Gas Chromatographs User Manual, P/N 3­9000-522, for more information.

Serial cable specifications:

• Straight-through serial cable with the following terminations:

• DB-9, maleconnects to GC Controller external serial port

• DB-9 or DB-25, femaleconnects to PC serial port

3. Interconnect Cable, P/N 6-4618-122, if not already installed between

the Analyzer and GC Controller. This is a shielded, computer and
communications grade, 15-conductor cable for making the thirteen
interconnections between the Analyzer and the GC Controller. This
cable, if not enclosed in conduit between the Analyzer and the GC
Controller, is suitable only for use in non-hazardous environments.
The cable must be run inside conduit for hazardous environments.
(For cable termination details, see Section 3.3.1, this manual.)

Installation and Setup 3-17

4. Direct Serial Connect Cable, P/N 3-2350-068, to connect the PC or an

external modem directly to the one of the GC Controller's serial ports
on the GC Controller's Terminal Board for Field Wiring (TB). This
cable comes in a customer-specified length. It is terminated with a
DB-9 female plug at one end, for connection to a PC or external
modem's serial port, and six exposed leads at the other end for
connection to the one of the GC Controller's serial ports on the TB.
(See Section 3.4.3.3 for directions on how to install this cable.)

5. Items necessary for connecting the GC Controller to an external

modem, a multi-drop serial network, or other type of remote data
transfer system (an example item might be an RS-232/RS-485
conversion box for long distance serial transmission).

JULY 2010 Optional Tools and Components

3-18 Installation and Setup

3.3 INSTALLING THE ANALYZER

3.3.1 Point-to-point Wiring Guide, Analyzer-Controller

Observe Precautions and

1

Warnings

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

Model 500 Gas Chromatograph

This section applies only to GC systems which have not been
shipped "prewired." In most cases, the explosion-proof system will
already have had the Analyzer-Controller connections made. If your
system has already been wired, skip this section, and proceed to the
next section.

To make wiring connections between the Analyzer and the GC
Controller, follow these steps:

1. Disconnect all electrical power to both the Analyzer and the GC
Controller.

INSTALLING THE ANALYZER JULY 2010

Model 500 Gas Chromatograph

2. At the Analyzer site, locate the lower explosion-proof box (its cover is

marked with original equipment manufacturer's catalog number
"XJT"). Remove its threaded Condulet cover.

Installation and Setup 3-19

Figure 3-2. Lower Explosion-Proof (XJT) Box at Analyzer

3. You will need to feed the Interconnect Cable through the inlet on the

upper left side of the XJT box, and make connections to the
interconnect Terminal Board (TB-4) which lies behind Valve Driver
board (see Figure 3-3).

(a) The Interconnect Cable is computer and control applications grade,

15-conductor, shielded cable. Individual conductors are stranded
tinned copper, #22 AWG-(7x30). (Also see description in Section

3.2.5, “Optional Tools and Components” on page 16.)

JULY 2010 Point-to-point Wiring Guide, Analyzer-Controller

3-20 Installation and Setup

(b) Maximum length of Interconnect Cable (or, the maximum distance

between the Analyzer and the GC Controller) should not exceed
2000 feet (610 meters).

Model 500 Gas Chromatograph

Figure 3-3. Behind the Condulet Cover is the Valve Driver Board, then TB-4

4. With the Condulet cover removed, loosen and remove the four (4)
thumbscrews that hold the Valve Driver board.

5. Carefully edge the Valve Driver board off the holding screws. Do not
disconnect the Valve Driver board from the cable; merely let the board
rest face down, secured by the cable (see Figure 3-4).

6. With the Analyzer TB-4 now exposed, connect thirteen of the
Interconnect Cable's fifteen leads to terminals 11 through 23. See

Table 3-1 and Figure 3-5 for purposes and destinations of leads. Also

see "CAUTION", step (6).

Point-to-point Wiring Guide, Analyzer-Controller JULY 2010

Model 500 Gas Chromatograph

Installation and Setup 3-21

Figure 3-4. Valve Driver Board Resting Face Down from its Cable Allows Access to TB-4

JULY 2010 Point-to-point Wiring Guide, Analyzer-Controller

3-22 Installation and Setup

Table 3-1. Analyzer and GC Controller Interconnect Leads

Board Acronyms:

• Interconnect Terminal Board of Analyzer (TB-4)

• Terminal Board for Field Wiring at Controller (TB)

Model 500 Gas Chromatograph

Analyzer (TB-4)

Terminal 11 Function code 1 J19, Terminal 1

Terminal 12 Function code 2 J19, Terminal 2

Terminal 13 Function code 4 J19, Terminal 3

Terminal 14 Function code 8 J19, Terminal 4

Terminal 15 Function code strobe J20, Terminal 1

Terminal 16 Common - function codes J19, Terminal 5

Terminal 17 Auto Zero (AZ) J20, Terminal 2

Terminal 18 Preamp gain channel 1 J18, Terminal 1

Terminal 19 Preamp gain channel 2 J18, Terminal 4

Terminal 20 Preamp gain channel 3 J18, Terminal 7

Terminal 21 Preamp gain channel 4 J18, Terminal 10

Terminal 22 Common - preamp gain J18, Terminal 11

Terminal 23 Alarm function (AF) J20, Terminal 3

color color

Controller (TB)

Connect the interconnect cable SHIELD to one terminal; specifically,
terminal 12 of J18, on the GC Controller TB.

Point-to-point Wiring Guide, Analyzer-Controller JULY 2010

Model 500 Gas Chromatograph

EQUIPMENT DAMAGE OR PERSONAL INJURY

Do not apply AC electrical power to the Analyzer or the GC
Controller until all electrical power, interconnection, and external
signal connections have been verified, and proper grounds have
been made. Refer to Section 3.1.3 for general precautions
concerning signal wiring.

Failure to properly connect the GC unit may result in serious
equipment damage or personal injury.

7. Access the GC Controller's Terminal Board for Field Wiring (TB), and

connect the other leads of the Interconnect Cable to the GC
Controller's TB (see instructions in Section 3.4.2, “Controller-Analyzer

Wiring” on page 35). Ensure that the connections correspond to those

listed in Table 3-1 and Figure 3-5.

Installation and Setup 3-23

At this time, you may also want to complete the remainder of all
electrical connections at the GC Controller. If so, see Section 3.4,

“Installing the GC Controller” on page 30.

JULY 2010 Point-to-point Wiring Guide, Analyzer-Controller

3-24 Installation and Setup

Model 500 Gas Chromatograph

Figure 3-5. Analyzer and GC Controller Interconnect Leads

Point-to-point Wiring Guide, Analyzer-Controller JULY 2010

Model 500 Gas Chromatograph

8. After confirming that all Interconnect Cable terminations are correct

between the Analyzer and the GC Controller, lift the Valve Driver
board from its resting position and place it over the four holding
screws.

Reinstall the four thumb screws to secure the Valve Driver board in
place.

9. If necessary, complete wiring connections between the Analyzer's

Valve Driver board and any optional stream switch boards.

10.If necessary, complete wiring for connecting AC power to the

Analyzer, with proper connections to hot, neutral, and ground; but do
not turn on AC power to the Analyzer yet (see CAUTION below;
see details for AC power connection to Analyzer in Section 3.3.2,

“Analyzer AC Power Wiring” on page 26).

Installation and Setup 3-25

EQUIPMENT DAMAGE OR PERSONAL INJURY

Do not apply AC electrical power to the Analyzer or the GC
Controller until all electrical power, interconnection, and external
signal connections have been verified, and proper grounds have
been made.

Failure to properly connect the GC unit may result in serious
equipment damage or personal injury.

11.Leave the Analyzer's lower XJT box open if you need to connect

sample and gas lines. (You will need to manually operate the sample
valve switches on the Valve Driver board.) Otherwise, reinstall the
Condulet cover of the Analyzer's lower XJT box.

12.If necessary, proceed to Section 3.3.3, “Sample and Gas Lines” on

page 27 for instructions on connecting sample and gas lines to the

Analyzer.

JULY 2010 Point-to-point Wiring Guide, Analyzer-Controller

3-26 Installation and Setup

3.3.2 Analyzer AC Power Wiring

Observe Precautions and Warnings

1

Plan Site Location

2

Obtain Supplies and Tools

3

Install Analyzer Wiring

4

To connect 115 volts AC Power to the Analyzer, follow these
steps:

1. Locate the three leads for connecting 115 volts AC-power to the
Analyzer.

(a) Leads are "pig-tailed" from the Analyzer power supply through

conduit to a customer power NPT connection directly behind the
lower XJT box of the Analyzer (see drawing CE-10492, Analyzer
drawings addendum of this manual).

Model 500 Gas Chromatograph

(b) Leads are colored as follows:

- BLACK: hot

- WHITE: neutral

- GREEN: ground

2. Connect Analyzer AC-power leads to a properly controlled 115 volts
AC-power source (i.e., with circuit breaker and power disconnect
switch).

SERIOUS PERSONAL INJURY OR DEATH POSSIBLE

Do not connect AC power leads without first ensuring that AC
power source is switched OFF.

Failure to observe all safety precautions could result in serious injury
or death.

Analyzer AC Power Wiring JULY 2010

Model 500 Gas Chromatograph

Make power line splices and conduit seals that comply with applicable
wiring requirements (for hazardous environments).

EQUIPMENT DAMAGE OR PERSONAL INJURY

Do not apply AC electrical power to the Analyzer or the GC
Controller until all electrical power, interconnection, and external
signal connections have been verified, and proper grounds have
been made.

Failure to properly connect the GC unit may result in serious
equipment damage or personal injury.

3. If necessary, connect the Analyzer's chassis ground to an external

copper ground rod (at remote locations). See Section 3.1.4, “Electrical

and Signal Ground” on page 8, regarding electrical and signal ground.

Installation and Setup 3-27

3.3.3 Sample and Gas Lines

4 Install Analyzer Wiring

5 Install Analyzer Sample & Gas Lines

6 Install GC Controller Wiring

7 Perform Leak Checks

To install GC sample and gas lines, follow these steps

Use stainless steel tubing. Keep tubing clean and dry internally to
avoid contamination. Before connecting the sample and gas lines,
flow clean air or gas through them. Blow out internal moisture,
dust, or other contaminants.

:

JULY 2010 Sample and Gas Lines

3-28 Installation and Setup

Model 500 Gas Chromatograph

1. Remove the plug from the Analyzer Sample Vent (SV) line (1/16-inch
tubing marked "SV", located at left side of Analyzer.

At this stage in the installation, the Analyzer Measure Vent (MV)
line (marked "MV") is left plugged until Analyzer leak checks are
completed. For regular Analyzer operation, however, the MV line
must be unplugged, or open.

HINT: Do not discard the vent line plugs. They are useful at any
time when leak-checking the Analyzer and its sample or gas line
connections.

(a) If desired, connect "SV" vent line to an external (ambient pressure)

vent. If the vent line is terminated in an area exposed to wind,
protect the exposed vent with a metal shield.

(b) Use 1/4-inch or 3/8-inch tubing for vent lines longer than 10 feet.

2. Connect carrier gas to Analyzer. (DO NOT TURN ON GAS AT THIS
TIME.)

See Appendix B, this manual, for a description of a dual-cylinder
carrier gas manifold (P/N 3-5000-050) with these features:

• Carrier gas is fed from two bottles.

• When one bottle is nearly empty (100 psig), the other bottle
becomes the primary supply.

• Each bottle can be disconnected for refilling without interrupting
GC operation.

(a) Use 1/4-inch stainless steel tubing to conduct carrier gas.
(b) Use dual-stage regulator: high side capacity 3000 psig; low side

capacity 150 psig.

(c) Analyzer carrier gas inlet is a 1/4-inch fitting located behind the

lower XJT Condulet box.

Sample and Gas Lines JULY 2010

Model 500 Gas Chromatograph

3. Connect calibration standard gas to Analyzer. (DO NOT TURN ON
GAS AT THIS TIME.)

(a) Use 1/8-inch stainless steel tubing to conduct calibration standard

gas.
(b) Use dual-stage regulator: low side capacity up to 30 psig.
(c) Calibration gas inlet is identified in the applicable Sample

Conditioning System ("S.C.S.") drawing in the Analyzer drawings

addendum to this manual. (See drawings CE-16120, CE-16220,

CE-16320, CE-16420, CE-16180, CE-16278, CE-24324, CE-24416,

or CE-24513.)

When installing the calibration standard gas line, take care to follow
the proper "S.C.S." drawing in order to make the correct tubing
connection to the auto-cal solenoid. Drawings are included in this
manual which address stream and column gas connections. Choose
the drawing that applies to your installation.

Installation and Setup 3-29

4. Connect sample gas stream(s) to Analyzer. (DO NOT TURN ON GAS
AT THIS TIME.)

(a) Use 1/8-inch or 1/4-inch stainless steel tubing to conduct

calibration standard gas.

(b) Ensure that pressure of sample line is regulated to maintain 15-30

psig ±10%.

(c) Sample gas stream inlet(s) are identified in the applicable Sample

Conditioning System ("S.C.S.") drawing in the Analyzer drawings
addendum to this manual. (See drawings CE-16120, CE-16220,
CE-16320, CE-16420, or CE-16520.)

5. After all lines have been installed, proceed with Controller wiring
connections (see next section).

Leak check procedures for the GC sample and gas lines are given in

Section 3.5.1, “Analyzer Leak Checks” on page 78. They require AC

power to be turned on at the Analyzer.

JULY 2010 Sample and Gas Lines

3-30 Installation and Setup

3.4 INSTALLING THE GC CONTROLLER

3.4.1 Modbus Slave Address (COM ID) Setup

4 Install Analyzer Wiring

5 Install Analyzer Sample & Gas Lines

6 Install GC Controller Wiring

7 Perform Leak Checks

The GC Controller's COM ID is determined by dual inline package
(DIP) switch settings. In most cases, the COM ID setup made at the
factory will not require changes. (Unless otherwise specified by the
customer, the DIP switch settings made at the factory give the
Controller a COM ID of 1 (one)).

Model 500 Gas Chromatograph

This section applies only to GC systems that have not been shipped
"prewired" or may not have had the COM ID set according to
customer specifications.

Follow the steps in this section only if you wish to do the following:

1. Change the GC Controller's COM ID, or

2. Visually inspect and verify the COM ID as determined by the DIP
switch settings.

Installing the GC Controller JULY 2010

Model 500 Gas Chromatograph

To inspect or change the GC Controller's COM ID setup, follow
these steps:

1. At the GC Controller site, locate the DIP switch as described in the
following steps.

SERIOUS PERSONAL INJURY OR DEATH POSSIBLE

Before removing the unit cover from the GC Controller, make certain
the power supply switch is OFF and the AC power cord is
disconnected. Observe all safety precautions when you are working
in a hazardous environment.

Failure to observe all safety precautions could result in serious injury
or death.

Installation and Setup 3-31

2. For the explosion-proof Controller, the front panel is secured by 16
screws. Remove those screws first.

Then carefully lower the front panel on its bottom hinges. The front
panel is heavy, so make sure it does not drop and cause damage. The
DIP switch is located on the lower left side of the front panel (see

Figure 3-6).

JULY 2010 Modbus Slave Address (COM ID) Setup

3-32 Installation and Setup

Model 500 Gas Chromatograph

Figure 3-6. Explosion-Proof Controller DIP Switch

3. For rack mount and panel mount Controllers, use a flat head screw
driver to remove the access panel on the right side of the card cage
assembly (see Figure 3-7).

Figure 3-7. Right Side View of Rack Mount and Panel Mount Controllers

Modbus Slave Address (COM ID) Setup JULY 2010

Model 500 Gas Chromatograph

4. Inspect or change the DIP switch settings as necessary.

(a) See Table 3-2 as a guide.
(b) Make sure you record in the GC Controller's maintenance records

any changes you make to the switch settings.

5. When finished with the inspection or changes, reassemble the

Controllers using the following steps.

(a) For explosion-proof Controllers, close the front panel and replace

the screws.

(b) For Rack mount and Panel mount Controllers, reattach the right

side Access Panel and secure with the four flat head screws.

Installation and Setup 3-33

Figure 3-8. COM ID DIP Switch

Explanation of DIP Switch Setting

• Switches "1" through "5" form a 5-bit binary number for setting the

Modbus slave address (also known as COM ID or Device ID.)

• Switch number "1" is the least significant bit, and switch number "5"

is the most significant bit.

• Switch to ON = 1

• Switch to OFF = 0

• Switch "6" is a spare for future use. Switches "7" and "8" are set as

needed for the presence of an optional LOI (Local Operator Interface)

JULY 2010 Modbus Slave Address (COM ID) Setup

3-34 Installation and Setup

Model 500 Gas Chromatograph

connected via COM8 When the COM4A Board is installed. If the
COM4A Board is not installed, the LOI is connected via COM4.

Table 3-2. Modbus Slave Address (COMID) DIP Switch Settings

Dip Switch Settings Switch Positions

COM ID12345

1 ON OFF OFF OFF OFF

2 OFF ON OFF OFF OFF

3 ON ON OFF OFF OFF

4 OFF OFF ON OFF OFF

5 ON OFF ON OFF OFF

6 OFF ON ON OFF OFF

7 ONONONOFFOFF

8 OFF OFF OFF ON OFF

RAM CLEAR

Dip Switch Setting Switch Positions

8

Clears RAM when unit powered down ON

Keeps RAM when unit powered down OFF

Modbus Slave Address (COM ID) Setup JULY 2010

Model 500 Gas Chromatograph

3.4.2 Controller-Analyzer Wiring

4 Install Analyzer Wiring

5 Install Analyzer Sample & Gas Lines

6 Install GC Controller Wiring

7 Perform Leak Checks

This section applies only to GC systems that have not been shipped
"prewired." In most cases, the explosion-proof system will already
have had the Controller-Analyzer connections made. If your system
has already been wired, skip this section, and proceed to the next
section.

Installation and Setup 3-35

Applicable to the digital and analog I/O lines connecting to the GC
Controller, including the Analyzer-Controller Interconnect lines: Any
loop of extra cable left for service purposes inside the GC Controller
explosion-proof housing must not be placed near the conduit entry
for AC power.

If the above precaution is not followed, the data and control signals
to and from the GC Controller can be adversely affected.

To make wiring connections between the GC Controller and
Analyzer, follow these steps:

1. Disconnect all electrical power to both the Analyzer and the GC

Controller.

2. Ensure that Interconnect Cable wiring connections to the Analyzer

have been made as explained earlier in Section 3.3.1, this manual.

JULY 2010 Controller-Analyzer Wiring

3-36 Installation and Setup

Model 500 Gas Chromatograph

3. At the GC Controller site, remove the Controller enclosure's front
panel.

(a) For the explosion-proof Controller, the front panel is secured by 16

screws. Remove those screws first.

(b) Then carefully lower the front panel on its bottom hinges. The

front panel is heavy, so make sure it does not drop and cause
damage.

(c) For the Rack mount and the Panel mount Controllers, the rear of

the enclosure is open; and an Access Panel on the right side of the
unit allows access for most field wiring procedures without
removing the enclosure.

4. Locate the GC Controller's Terminal Board for Field Wiring (TB). The
TB is attached to the GC Controller's card cage assembly, facing the
enclosure's front panel. (In the Rack mount Controller, the TB faces
outward toward the rear of the enclosure.)

5. Route the Analyzer-Controller Interconnect Cable appropriately,
especially in the case of the explosion-proof Controller enclosure.

Figure 3-9. Seperate Conduit Entries for Cable In/Out of GC Controller

Controller-Analyzer Wiring JULY 2010

Model 500 Gas Chromatograph

6. Make Interconnect Cable wiring connections to the GC Controller TB

as listed earlier (see Section 3.3.1, “Point-to-point Wiring Guide,

Analyzer-Controller” on page 18 and Table 3-1).

3.4.3 Controller PC Wiring (Serial Connections)

4 Install Analyzer Wiring

5 Install Analyzer Sample & Gas Lines

6 Install GC Controller Wiring

7 Perform Leak Checks

A preferred method for operating a Model 500 Analyzer System is from a
connected personal computer (PC). The PC must be:

• Running MON2000 software

Installation and Setup 3-37

• Connected to the GC System by a serial link

This section of the manual addresses the various possibilities for wiring a
serial connection between a PC and the GC System.

Before Connecting

Before connecting a PC to the GC Controller, determine the
following:

JULY 2010 Controller PC Wiring (Serial Connections)

3-38 Installation and Setup

Model 500 Gas Chromatograph

• What serial ports are available at the PC? When you select one,
consider these points:

- Standard PC serial ports are type RS-232.

- Usually there are two external serial port jacks on a PC, located on

the rear panel. Most often, they are either DB-9 or DB-25 male
(see below).

- PC serial ports can be designated as "COM1" through "COM8," and

they can be used by other peripheral equipment attached to the
PC, such as printers, mice, or modems, etc.

You will need to connect the GC Controller to one of the PC's
available, or unused serial ports.

To determine which PC serial ports are already being used by
other equipment and which port can be used for connecting to the
GC Controller, note existing serial connections, refer to your PC
user's manual, and use diagnostic software (such as Norton
Utilities™).

Controller PC Wiring (Serial Connections) JULY 2010

Model 500 Gas Chromatograph

• What serial ports are available at the GC Controller? When you select

one, consider these points:

- The GC Controller's COM1 serial channel is usually reserved for
connecting a PC, especially for service or troubleshooting purposes,
since the GC Controller's easy-access front panel serial port is
connected to serial channel COM1.

Installation and Setup 3-39

Figure 3-10. The Front Panel Serial Port is Connected to GC Controller’s Serial Channel COM1

- COM8 is used for the display/keypad when unit has COM5-8
option (COM4A Board). However, when the unit has a display/
keypad but does not have the COM8 option, COM4 must be RS­232, and is used for the display/keypad. Therefore, there is no
COM4 output on the field Terminal Board.

- The optional Modem piggy-backs on to the CPU 104 BUS (See
Internal Modem for the Model 2350A Gas Chromatograph,
drawing BE-20767).

JULY 2010 Controller PC Wiring (Serial Connections)

3-40 Installation and Setup

- Any one of the Controller's eight serial channels could also be
reserved for connecting to a Data Collection Systems (DCS) or
multi-drop serial data highway system (and thus, would be
unavailable for a serial PC connection).

• Is the connection to be made in a...

- Nonhazardous environment?

- Short distance between the PC and Controller?

- With temporary or permanent cable connection?

See “PC-to-GC, Front Panel Quick and Easy RS-232” on page 40.

• Is the connection to be made in a...

- Hazardous or nonhazardous environment?

- Short distance between the PC and Controller?

- Permanent cable connection?

Model 500 Gas Chromatograph

See “PC-to-GC, Permanent Cable Connection for Short Distance RS-

232” on page 41.

• Is the connection to be made with a...

- Long distance between the PC and Controller?

- Permanent cable connection?

See “PC-to-GC, Long Distance with RS-422 or RS-485” on page 43.

PC-to-GC, Front Panel Quick and Easy RS-232

The easiest way to connect a PC to the GC Controller is with an 'off-the­shelf', straight-through serial cable connected to the GC Controller's front
panel DB-9 serial port jack.

Controller PC Wiring (Serial Connections) JULY 2010