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Model 500 Gas Chromatograph Hardware Reference Manual

1. segue Notes m ia AX CONNECTIONS FOR TEMPERATURE MEASUREMENTS rele DEGENTES Gs mee 4 m gt CUSTOMER NOTE TYPE J THERWOCOUPLE MRE ONLY m z BUT SEE n OMR METAL DELE p iei ome AX WRES 3 BLK WHT AND GRN TO BE PIGTAILED IN PI uywa AX WRES 2 WHT AND RED FROM PRESSURE e Ec mere a El met a B meer Ej E mere rc a mun NE CARI zt SEED Sic eme 6 ria saame EMERSON Da SERR stc owes v pa seco oria eee ree oo pE 18301 D MI TIC E Gr WE fea E P m NOTES erg up scie wen eon esos oF au wt Gn o n A EM 5 PORT VALVE ASSEMBLY INSTRUCTIONS SOLERE Scl wi We CHEE mh ad PCR us JUS SU re Orts amupa nanan am q Sarsa HA D 3 5 EZS S NCLOSURE REMOVAL CLEARANCE 5008 CLEARANCE rs EM
2. TAES NOTES ANALYZER OVEN AL guar comeenins are nae SAMPLE vent 4179 uy sow WH vs CAL STD N gt S 59 ax SOLENOID wene STREAM 1 hs BEES E E BYPASS 1 aH f STREAM 2 et BYPASS 2 4H LEGEND STREAM 3 B iles TOC BYPASS 3 aH es Mos ROCA 0 At sar SCS PAE 5 m eum mee ines ma REET pce Management EL ers uu BAS PT wa U mi am me ool miser sa RIE T nsa manana pest n e inl 21 1 esa P xr CAL STD IN STREAM 5 STREAM 1 STREAM BYPASS 1 STREAM BYPASS 2 S C S PLATE NOTES 1 ALL CUSTOMER CONNECTIONS ARE 1 8 SWAGELOK TUBE FITTINGS UNLESS NOTED SOLENOID WIRING TB4 IS LOCATED IN LOWER ELECTRONICS ENCLOSURE BEHIND THE VALVE DRIVER BOARD REF DE 10493 4 5000 112 FILTER INLINE 1 8 4 5000 109 BLOCK VALVE 1 8 V ESTES 5 10 4 5000 202 VALVE REG 1 8 THIRD ANGLE PROJECTION AERA N A m 4 30 05 HM RELEASED EM N A REV DATE DRN DESCRIPTION CHKD B 10 19 05 HM ECO XX 5001209 EM FILENAME CE24416B1 DWG DATE 10 18 05 TIME 2 51 P M THIS DRAWING IN DESIGN AND DETAIL IS WORK IT SHALL NOT BE REPRODUCED DIMENSIONS PER
3. la ye E E CARRIER er Mie fo a Tuet hmm FOR SIGNAL FOR DE 13081 Erg so bi a us _ 5 ry py 2109 custower power Sis so Da ku M E eo te Ewes 1800 Hot NEU oxo MONT hours CustoueR cowecrons E scs REFER To Situ 4 M H 388 na Tt REF REF ar Pale FRONT ERONT VIEW RIGHT SIDE VIEW BACK VIEW AS MOUNTIN ELL OEN EEE EAE PEON j z Tea x eexcwuss orpr ONT t gio 7d EE s OUTLINE AND DIMENSIONAL umm 5 16 04 tco xx 205632 tw ur EMERSON MODEL 500 G C Wk s jua CSET as IE geen EG ERES T TI e aa ww Sua CE 23858 T TEE mU E aet m s sur PTS N 2 AR Me Locum 23504 CONTROLLER LEFT SIDE ERN MC imm koa s ir eh s ie HOLT yer ERE CE 23878 EGRE xx nive rein ac PRA a
4. 5 5 SERVICE TROUBLESHOOTING AND REPAIR INSTRUCTIONS E 5 5 1 Preamplifier 5 10 5 5 2 Temperature Control 5 10 55 3 Decoder 540 5 5 4 Analyzer Troubleshooting Guide 5 5 5 Chromatograph Valves 522 5 5 6 Detector Bridge Balance 523 Maintenance JULY 2010 TABLE OF CONTENTS 6 Model 500 5 5 7 Temperature Measurements 5 25 5 5 8 Measure Vent Flow MV 527 5 5 9 Analog Inputs 527 5 6 GC CONTROLLER MAINTENANCE 5 6 1 57 COMMUNICATIONS 5 7 1 GC Controller Address Change 58 ANALOG INPUTS AND OUTPUTS 5 8 1 Analog Output Dialog Description 5 8 0 Changing a Variable 5 8 3 Changing the Bargraph 5 8 4 Performing a Manual Calibration 5 8 5 Performing an Automated Calibration 539 5 8 6 Analog Loopback Test Circuits 5 8 7 Upgrading Analog Outputs 543 5 9 DISCRETE DIGITAL INPUTS AND OUTPUTS 5 44 5 9 1 Digital Loopback Test Circuit 544 5 10 FUSE PROTECTION 545 5 11 ANALYZER CONTROLLER INTERCONNECT 5 46 5 11 1 Function Code 5 48 RECOMMENDED SPARE 6 1 ANALYZER SPARES 64 PARTS 6 1 1 Printed Circuit Card Assemblies Analyzer 6 1 6 1 2 Electrical and Mechanical Assemblies Analyzer 6 1 62 GC CONTROLLER ea 6 2 1 Printed Circuit Card Assemblies GC Controller 6 2 2 Electrical and Mechanical Components GC Controller 63 2010 Recommended Spare Parts gt TABLE OF CONTENTS Model 500 APPENDIX A SUPPLEMENTAL W
5. REF FLOW PANEL EH DETECTOR ANALYZER OVEN RI 1 16 X 004 LD MATCHES THE RESTRICTION OF COLUMN 3 2 FLOW PATH VALVE ENERGIZED FLOW PATH VALVE DE ENERGIZED O CARRIER Isb 1 DRYER DET TOP VIEW OF ANALYZER OVEN FROM FRONT G o3 20 09 cc ECO XX 5004591 LF THIS DRAWNG IN DESIGN AND DETAL IS OUR PROPERTY AND MUST NOT USED EXCEPT IN CONNECTION WITH OUR Wom IT SIALL NOT BE REPRODUCED AND SHALL BE RETURNED TO US ON DEMAND ALL RIGHTS ARE RESERVED THIRD ANGLE PROJECTION F 5 3 05 ECO XX 5000713 DLT our m t 6 26 01 Ro ECO XX 118907 SB INST Vids amp LATEST REVISION D 09 22 00 RD Der FLOW CONFIGURATION c 09 94 RH wee wro EMERSON BACKFLUSH TO MEASURE B 09 92 AH RH imo im Process Management DUAL COLUMN WITH SSO A 08 92 AH RH DAE 07 20 92 WG FL ME 1 BH IUD SSCS SE te ONE 08 92 17204 G NONE FILENAME BE17204G1 DWG DATE 03 20 09 TIME 11 00 AM woes sce ORDER I 1
6. DIGIALUO 32350 THD Hi Pwr Discrete Output M5 Din D M1 Din 25 CURRENT MS Dout 5 NOTES 16 pin DIGIALUO 32350 019 Hi Pwr Discrete Output MS Dout 1 1 CURRENT NOTES 20 pin suty 2010 PART APPLICATIONS NUMBERS AND DESCRIPTIONS 5 Guide to Transient Protection Modules Model 500 Gas Chromatograph TROUBLESHOOTING TRANSIENT PROTECTION MODULES To determine the integrity of a transient protection module follow the guidelines in these tables see Tables C 2 C 3 and C Table C 2 Troubleshooting TPM P N 3250 002 PIN 32300002 16 pin Quad Sng Tost ControllerAnalyzer Interconnect Stream Switch and Digital UO ow current VISUAL INSPECTION MOVs MEM Good Blue in color Failed Diseolored to brown or black Resistors RIRA Good Intact Failed Broken or open EQUIPMENT DAMAGE Remove transient protection module from board before all omma checks Failure to do so may cause equipment damage OHMMETER CHECK MOVs MIMS Good Open or infinite ohms Failed Shorted or 0 zero ohms Resistors RRA Good 330 ohms Failed Open infinite ohms or short 0 ahm Diodes Good Open infinite ohms in one direction and 4 12 megohms in the opposite direction Failed Short 0 ahma in one ar both directions TROUBLESHOOTING TRANSIENT PROTECTION MODU
7. 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 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 eap 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 Use liquid tight conduit fittings such as Seru titet 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
8. VERSION 3510822400 BUILT 08 11 2008 133537 A PERIPHERAL DEUCE PO USB SID AND PC 104 BUSSES PERPHERAS SERAL PORTS PORT A ADDR D40338 PORT B ADOR 0 O2F8 PORT C ADOR OrOJEB PORT D ADOR 0r02EB PARALLEL PORTS ENABLED ADOR 04278 IRQ NONE MODE COMPATIBLE on ASSIGN RO 12 TO MOUSE DISABLED oencs INTERNA CONTROLLER MODE SECONDARY CONTROLLER OUTPUT DISPLAY PANEL AND CRI FLAT PANEL CONFIGURATION RESOLUTION 640x480 0 PC AND STD BUSSES PCI INTERRUPT STEERING NIA NONE NONE PCI NTC NONE PONTO NONE E Peis Bus PC 104 INTERRUPT STEERING TOS DISABLED MOs ENABLED AROS DSABLED ROG DISABLED ENABLED 1808 DISABLED 1010 ENABLED IRANI ENABLED 18016 DSARED 18015 ewen Ea Teas Tw ORES puna sam nanas 1 wm e CEE TE EMERSON Bono some _ eoon bi rece Management 3500 x rans sex l we om own Epa C CLIPASC DE 0 30 05 TUE 850 AN MNT jue oiii ES N SET JUMPERS AS FOLLOWS DES 21212 B 1 2 2 NOT usen LOAD THE LATEST VERSION OF REPRESENTED BY XXX HERE TO THE COMPACT FLASH ME
9. BURRS PDT DATE 2 19 02 SEE ORDER S4 UNLESS OTHERWISE NOTED ECO XX 203411 ALL DIMENSIONS IN INCHES X XXX 005 ERO YY 10078 DLT NS Co lt gt cC Ro DRN N N M10 1 5 TAP 500 12 7 DEPTH FULL THD 4 PLACES BACK VIEW 12 4 I 13 314 4 44 1 11 1 282 4 SIDE VIEW ro 3 50 1 11 1 2 NPSM TAP THR 88 9 OR OPT ONAL METRIC 2 00 M25 15 TAP THRU 50 8 0 Q Q mI c Fa M EN 6 00 KZ oe 2 11 1 2 NPSM TAP THRU OR OPTIONAL METRIC M10 1 5 TAP 625 15 9 DEPTH FULL THD 4 PLACES 4 75 120 6 LO 12 5 318 2 BOTTOM VIEW UNACK ALARM WORKING ACTIVE ALARM le 326 1 2 E E E e e s DO NOT OPEN e WHILE EXPLOSIVE EMERSON MIXTURE IS PRESENT Process Management 443 THIS DRAWING IN DESIGN AND DETAIL IS OUR PROPERTY AND MUST NOT BE USED EXCEPT IN CONNECTION WITH OUR WORK IT SHALL NOT BE REPRODUCED AND SHALL BE RETURNED TO US ON DEMAND ALL RIGHTS ARE RESERVED GEOMETRIC TOLERANCES amp wasi E DIMENSIONS PER ERE ANSI Y14 5 SI METRIC THIRD ANGLE PROJECTION P m E MATERIAL RH REV CO 203411 DLT X XX X XXX 005 ROW 10078 ie E 200 RA MAX N A REV DATE DRN DESCRIPTION CHKD APPD BREAK AL SHARP CORNERS 10 DE 20779 003 015 RADIUS AND REMOVE DATE 1 10 02 PROJ FILE NO
10. Ifan unacceptable parameter has been entered enter a new or valid parameter Valid parameters are normally established as part of the application software The range requirements are described as part of the individual parameter description uiv 2010 Validity Checks of Data Entries Model 500 Gas Chromatagraph 43 Data identification tags will appear to the right of any data box on the display to indicate the type of entry expected These identification tags will help you make valid entries Data identification tags and the corresponding valid entries are as follows string size limited to 12 digit insertions b byte II integer limited to numbers 1 long byte integer f oat byte floating point number double 8 te floating point number t toggle switch from one entry to another with SPACE m time q sequence stream series x text multiple letters digits none none edit field LOCAL DISPLAY MENUS The local display Main Menu has seven items listed each of which branches into another menu This is illustrated below in the menu tree diagram Figure 4 4 and explained further in the sections that follow Refer to MON2000 Software for Gas Chromatographs User Manual P N 3 9000 522 for detailed information regarding the commands and functions that follow LOCAL DISPLAY MENUS JULY 2010 Model 500 Gas Chromatograph Operation from Local Keypad and Displ
11. Valve d OFF Valve 50N Valves OFF Stream 3 The Function Code Strobe measured at sith TBA 15 occurs 1 one second or J20 1 or the Analyz more following any given event the GC Controller Function Code Common is at these terminals GC Controller TB J19 5 and the Analyzer 16 see Figure 5 9 Juy 2010 Function Codes Maintenance Model 500 Gas Chromatagraph Table 5 7 Function Code Dictionary in Hexadecimal INPUT hexadecimal VALVE SET ON VALVE RESET OFF D Analyzer Valve 1 av AVS J AV n 5 Ava AV D Stream Valve sva 5 3 sva SVA 4 5 FZI BV12 22 c SVS 2 8 4 5 r AV E urement of 5 ive volts at any of the function code Terminals indicates a binary zero 0 A measurement of O zer Volts indicates a binary one 11 Function Codes 2010 Maintenance 5 51 Model 500 Gas Chromatograph This page is intentionally left blank uiv 2010 Function Codes 5 52 gt Maintenance Model 500 Gas Chromatograph Funetion Codes JULY 2010 RECOMMENDED SPARE PARTS 64 64 Following are lists of recommended spares for approximately a year s maintenance of the Model 500 Analyzer System Maximum quantiti
12. Alarm Specifications uty 2010 INSTALLATION AND SETUP raph system is av different configurations not 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 Introduetion Site Seleetion 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 lt 3 2 gt Installation and Setup Model 500 Gas Chromatagraph Installing the GC Controller Modbus Slave Address COM ID Setup Controller Analyzer Wiring Controller PC Wiring Serial Connections CPU and Serial Communications Setups Controller Printer Wiring Discrete Digital VO Wiring Analog UO Wiring Controller AC Power Wiring Analyzer Leak Checks and Purging for First Calibration Analyzer Leak Checks Purging Carrier Gas
13. If additional analog outputs are installed specific transient protection modules must also be installed on the GC Controller s Terminal Board for Field Wiring TB For details about transient protection modules see Appendix C Also see drawing CE 18115 sheet 2 in the GC Controller drawings addendum this manual Once the Analog Board System Interface Board and the proper transient protection modules are installed field wiring for the added analog outputs from the GC Controller are made to GC Controller TB ports J13 and J1 NOTICE Previous versions of the Controller manufactured before March 1998 used two boards for analog outputs RTL 1281 for standard two outputs and RTI 1282 for optional additional analog outputs If you are replacing RTI 1281 and 1282 Analog Boards with a newer single Analog I O bo use MON2000 Software Version 1 5 or later to oper Chromatograph uiv 2010 Upgrading Analog Outputs 5 44 gt gt Maintenance 5 9 DISCRETE DIGITAL INPUTS AND OUTPUTS Model 500 Gas Chromatagraph For instructions on connecting digital inputs and outputs to the GC Controller see Section 3 4 6 and drawing DE 20782 GC Controller drawings addendum this manual 5 9 1 Digital Loopback Test Circuit An external loopback test circuit can be built for troubleshooting the GC System s digital input output operation See Figure 5 8 e Yes EE CO
14. sult in serious injury 4 Use the previously completed wiring diagrams and color boxes completed previously in Section F 2 to reconnect the Model 500 Analyzer printer and strip chart recorder to the 2350A GC Controller 5 Review the wiring diagrams and color eode boxes you completed to verify each wire has been terminated correctly 6 Turn ON the 20 volt power switch to the Analyzer by turning ON the top three switches in the lower explosion proof electronies housing described earlier in step 1 above Section REMOVE CABLES REPLACE CONTROLLER AND RECONNECT JULY 2010 Upgrading from 2251 to 2350A GC Controller F 7 Model 500 Gas Chromatograph 7 Connect the 2350 GC Controller power cord and turn ON the AC power to the Controller 8 Follow the software installation procedures provided with the new MON2000 CDs a You will need to connect a personal computer PC to the 2350A GC Controller in order to first operate it and download GC Applications to it b For startup of the 2350A GC Controller in the field a laptop computer and RS 232 serial cable connection is recommended Hazardous environments require a remote connection e A straight through commercial serial cable connected between the PC and the 2350A GC Controller s front panel serial port will suffice in most instances See Figure 4 for terminals and pinouts for possible RS 232 serial connections to the 2350A GC Controller
15. EMERSON wo ite Sn Esso aoa 2 la D DED NOTES INSTALL 2 POSITION JUMPERS AND I m AS INDICATED FOR USE WTH Je 1 2 3 4 5 6 7 8 o 1 3 2 2 8 23 20 ue INFERS 2 9 PER ALE ET pes s REMOVE OR hom K s PER HOLE 2 ASK orr cotone 5 8 sockens COMETS or a Ego pea m Bale elle a cs A E ue GHEE RPGS CONGR six vs is 00 BRADY LES BACK OF A A N us unt uta ARE AS0CHIED WTH cou 7 s a us uz us AN0 st ARE ASSOCHTED WH EE Li oy NBOOBBBBE anette BEHERE GEE EE EERE BEE oe m pum eer rem Cascos 2 2 In 99 U Uk UX UA on UE t lt aoe rows ees mie 2 O w ox us wa n us RET EET EE Ere i cc EM er rae ee ERE pe Cero w ESIR ufe ner gg EMERSON cow sen
16. The MAINTENANCE LOG menu allows the operator or maintenance personnel to view historical maintenance actions add any pertinent maintenance entries into the log and or change entries as necessary The PC Config Report requests the control to output a config report The report will be printed on the Controller s printer Maintenance Log 1 Reports 2 PC Config Report 3 Maintenance Log uiv 2010 Data Records Menu 4 18 gt gt Operation from Local Keypad and Display Model 500 Gas Chromatagraph This page is intentionally left blank Contig Rpt Maint Log Menu JULY 2010 MAINTENANCE This section provides instructions and checklists for maintaining or yaparina the Model 500 Analyzer System Thi section is organized as Troubleshooting and Repair Concept Routine Maintenance Model 500 Analyzer Maintenance Checklist Routine Maintenance Procedures Contract Service Locating and Gaining Access to Equipment Elements Analyzer Electrical Electronic Units Detector Elements Heater Elements Valves and Columns Precautions for Handling Printed Circuit Assemblies Service Troubleshooting and Repair Instructions Preamplifier Temperature Control Decoder Analyzer Troubleshooting Guide Chromatograph Valves Detector Bridge Balance Temperature Measurements Measure Vent Flow MV Analog Inputs GC Controller Maintenance GC Controller Access Communications GC Controller
17. 34 7 Analog I O Wiring Install Analyzer Wiring 3 _ Install Analyzer Sample amp Gas Lines Install GC Controller Wiring 7 Perform Leak Checks connect analog signal input output lines to the GC Controller follow these steps 1 Access the GC Controller s Terminal Board for Field Wiring TB Analog UO Wiring suy 2010 Installation and Setup 3 75 Model 00 Gas Chromatograph 2 Route analog UO lines appropriately especially in the case of the explosion proof Controller enclosure SIGNALS TO AC POWER OTHER FROM SIGNALS ANALYZER Figure 3 27 Seperate Conduit Entries 3 Make analog T O connections to the GC Controller TB In standard configuration there are connections for four analog input and two analog output lines as follows a Analog Inputs GC Controller TB connection port J12 Analog Outputs GC Controller TB connection port J14 b For specific pin number assignments see drawing DE 20782 GC Controller drawings addendum this manual uiv 2010 Analog O Wiring 376 Installation and Setup Model 500 Gas Chromatagraph As an option the Series 2350A GC Controller can be configured with additional analog outputs there are two analog outputs on the Standard Analog Board PIN 3 2350 041 For more analog outputs the existing Analog board must be exchanged for one of these optional Analog Boards allowing a quantity of either six or
18. 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 the MON2000 Software program This user interface offers the greatest amount of eapability and flexibility For instructions see the MON2000 Software for Gas Chromatographs User Manual PIN 3 9000 522 The GC Controller s built in keypad and Liquid Crystal Display LCD This offers only essential startup and operation functions but is useful in a hazardous environment or if no PC is available See Figure 4 1 the display keyboard uses COMA and it must be RS 232 Therefore there is no output on the Field Termination Board This section only addresses using the GC Controller s built in keypad and LCD This section is organized as follows ion from Local Koypad and Display Model 500 Gas Chromatograph Interface Components for Local Data Display and Entry Light Emitting Diode LED Indicators Liquid Crystal Display LCD Keypad Logging On to View or Edit Data First Time Log On Subsequent Log On Start Halt an Auto Sequence Analysis Editing Procedures Validity Checks of Data Entries Local Display Menus Main Menu Hardware Menu Operator Entries Menu Alarms Menu Chromatogram Menu GC Control Menu Data Records Menu Config Rpt Maint Log Menu JULY 2010 Operation from Local Keypad and Display lt 4 3 Model 500 Gas Chromato
19. c Set Usage to Report Pricl to ASCII and RW to W Controller Printer Wiring suty 2010 Installation and Setup 3 71 Model 500 Gas Chromatograph d Set all other settings to default values Le Stop Bits 1 Parity None RTS On 0 Digital UO Wiring Analyzer Wiring 5 Install Analyzer imple amp Gas Lines Install GC Controller Wiring 7 Perform Leak Checks To connect digital signal input output lines to the GC Controller follow these steps 1 Access the GC Controller s Terminal Board for Field Wiring TB 2 Route digital UO lines appropriately especially in the ease of the explosion proof Controller enclosure Refer to Drawing P N DE 20782 SIGNALS TO ACPOWER ALLOTHER ANDFROM SIGNALS ANALYZER uiv 2010 Discrete Digital VO Wiring 3 72 gt Installation and Setup Model 500 Gas Chromatagraph Figure 3 25 GC Controller Conduit Entries 3 Make digital I O connections to the GC Controller TB There are connections for five digital input and five digital output lines as follows a Digital Inputs GC Controller TB connection ports J7 and J9 Digital Outputs GC Controller TB connection port J8 b For specific terminal or pin number assignments see drawing DE 20782 GC Controller drawings addendum this manual 4 To enable digital input signals also make these jumper wiro connections see Figure 3 2
20. 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 coven e 190 Scone where CONCN Normalized concentration of component in percent of total gas CONC Non normalized concentration of component n in mole percent CONC Non ormalized concentration in mole percent from each of the k components to be grouped into this normalization D Number of components to be included in the normalization uiv 2010 Basic Analysis Computations 1 16 Description Model 500 Gas Chromatograph For additional information about other calculations that are performed by the GC Cont 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 haseline 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 typical chromatogram displays all component peaks and ga
21. on page 4 1 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 displayedientered 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 display 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 few adjustments will he more conveniently accomplished at the Controller site uty 2010 Optional Keypad and Display 2 26 Equipment description Model 500 Gas Chromatograph 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
22. Board on page H 8 Ifa COM4A board was not installed and you want to install a keyboard and display go to Installing a Keyboard and Display without COM4A Board on page H 9 9 Ifa Com4A board was not installed and you do not want to install a keyboard and display then proceed to the next step 10 Plug the end of the ribbon cable PIN 3 2350 084 Rev C labeled CPU J6 into the CPU header labeled J6 plug the end of the ribbon cable labeled INTF J10 into the header on the System Interface Board labeled J10 for access to serial port 4 on the field termination board plug the end labeled INTF J8 into the header on the System Interface Board labeled J8 for access to serial port 3 on the field termination board The CPU board installation is complete If you plan to install a new analog board go to Retrofitting the Analog Board on page H 11 otherwise go to Reassembling the 2350A on page 13 uiv 2010 Installing the New CPU Board 117 CPU to LX B00 CPU Upgrade Instructions Model 500 Gas Chromatograph INSTALLING KEYBOARD DISPLAY WITH COM4A BOARD connect a keyboard and display to a CPU assembly with COM4 board do the following 1 Plug the 20 pin connector labeled CPU J6 from the ribbon cable PIN 2 2350 084 rev C into the J6 connector on the CPU board 2 Plug the 10 pin connector labeled INTF J10 into the header labeled J10 on the system interface hoard for
23. DB 9 male plug at the other end for GC connection You can buy this type of cable with plug ends already installed from most computer supply retailers so there should be no need to custom wire a serial cable for this type of connection however it is necessary to custom wire a cable because of circumstances see guidelines provided in Appendix A this manual 2 Connect the serial eable s plugs to the appropriate serial port jacks at the PC and GC front panel Then use the MON2000 Software to Connect and operate the GC as needed PC to GC Permanent Cable Connection for Short Distance RS 232 Another way to connect a PC to the GC Controller is with straight through serial cable connected to one of the GC Controller s internal serial ports located on the Controller s Terminal Board for Field Wiring TB Ifthe length of cable can be 50 feet or less connect the serial cable to one of the GC Controller s serial ports configured for RS 232 Recall that uiv 2010 Controller PC Wiring Serial Connections 3 42 Installation and Setup Model 500 Gas Chromatagraph output from a standard PC serial port follows RS 232 serial definition Cable that is longer than 50 feet when used for RS 232 serial transmission can result in spurious loss or corruption of data To connect a PC to one of the GC Controller s internal serial port jacks proceed as follows 1 Access the GC Controller s Terminal Board for F
24. Model 500 Gas Chromatograph Hardware Reference Manual Applies to Both Daniel Danalyzer Model 500 Rosemount Analytical Model 500 3 9000 537 K JULY 2010 EMERSON Model 500 Gas Chromatograph System Reference Manual NOTICE DANIEL MEASUREMENT AND CONTROL INC AND ROSEMOUNT ANALYTICAL COLLECTIVELY 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 MAINT
25. SERIOUS PERSONAL INJURY OR DEATH POSSIBLE leads without first ensuring that AC Failure to observe all safety precautions could result in serious injury or death 1 Access the GC Controller s Terminal Board for Field Wiring TB If necessary s instructions provided in Section 3 4 1 step 1 2 Locate the AC power connection terminal group on the TB It labeled J21 and has three connection points labeled 1 HOT NEU and 3 GND Also see drawing DE 20782 in the GC Controller drawings addendum this manual 3 Connect AC power leads from a properly controlled 115 or 230 volts AC power source i e with circuit breaker and power disconnect switch to terminal J21 on the Controller TB a The Controller has a transformer that will accept either 115 volts or 230 volts b Ensure that the power source leads are properly connected to the HOT NEUTRAL and GROUND terminals Generally the color uiv 2010 Controller AC Power Wiring 2 78 gt Installation and Setup Model 500 Gas Chromatagraph convention for these wires is HOT black NEUTRAL white and GROUND green e 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 Failure to properly connect the GC unit may result in serious equipment damage or personal injury 4 If necessary connect the Controller s ch
26. from sample probe to sample solenoid MODEL 500 INPUTS raz zwrAD Value a2bhir AD PAZ AD Value Gobi AD 1 0 01000 600 to 00 Tto 4095 4800 to 6100 32767 to 32767 2 1 600 0 800 064095 1800 to 6100 32767 to 32767 a 600 0 800 064095 1800 to 6100 32767 to 32767 a 98 ra 1150 01500 oto 4095 9200 ta 12000 32267 to 32767 ANALYZER POWER SUPPLY Volts 200 25V TB4 Terminals 20V 24 common Volts 20 045 25 20 Volts and 20V 28 20 Vols 20V mV AC 0040 mV C2 AC mV CHROMATOGRAM Check baseline Check component values on report Number of peaks Retention times Date and file 2010 Analyzer Troubleshooting Guide 546 Maintenance Model 500 Gas Chromatograph AS FOUND AS LEFT NOMINAL TEMPERATURE see par 5 Detector Temperature Cor Cor Thermocouple Wire 1 Type J E Heater Block Temperature Cor Cor Thermocouple Wire 2 Type J E Sample System Temperature f C applicable MEASURE VENT FLOW Gee par 5 5 8 Analyzer Valve 3 ON emmin comin 12 18 comin Analyzer Valve 3 OFF comin comin Refer to System Operational Parameters Leak Checking the Analyzer Plug all Analyzer vents Make sure the setting of the carrier gas cylinder regulator is 115 pounds per square inch gauge psi
27. owt WON 2 COLE doce L men RE ice Figure 5 1 Upper Esplosion Proof Housing Electrical Components Analyzer Eloctrical Eactronic Units uiv 2010 Model 500 Gas Chromatograph 532 54 The following circuit assemblies are located inside the upper explosion proof housing Temperature controller valve driver printed circuit assembly on the left side of the housing The preamplifier printed circuit assembly on the right side of the housing Decoder control printed eircuit assembly which is reached by unplugging the temperature controller valve driver and the preamplifier printed circuit assembly D tector Elements H r Elements Valves and Columns Tho detector elements heater elements valves and columns are located in the upper section of the Analyzer To gain access to these components remove the gray insulation The detector elements are located in the upper explosion proof housing in front of the heater block To gain access to the detector elements remove the threaded cover plate The heater elements are inserted in the bottom of the heater block The columns are located inside the top of the block To gain access to the columns remove the top cover plate PRECAUTIONS FOR HANDLING PRINTED CIRCUIT ASSEMBLIES Printed circuit assemblies contain CMOS integrated circuits which can be damaged if the assemblies are not properly
28. uiv 2010 REMOVE CABLES REPLACE CONTROLLER AND RECONNECT F 8 gt Upgrading from 2251 to 2350A GC Controller Model 500 Gas Chromatograph Model 23508 COMM PORT 1 Model 23504 P2 ribbon cable also goes QU cum um T nsn H osr at i a a Figure F 4 Terminals and Pinouts for Possible RS 282 Serial Connections to the Model 2350A GC Controller REMOVE CABLES REPLACE CONTROLLER AND RECONNECT JULY 2010 APPENDIX 6 2350 TO 2350A CPU RETROFIT INSTRUCTIONS 2350A CPU ASSEMBLY INTRODUCTION The 2350 GC Controller CPU assembly has been designed to include al digital UO and and serial porta This eliminates the requirement and additional cost for an UO assembly or DSPI O assembly In addition BOS is now resident in the DiskOnChip instead of an EPROM set The DiskOnChip provides additional expanded memory for archiving data instead of having to purchase a memory expansion board assembly The BOS file in the DiskOnChip may be upgraded in the field through the MON2000 Software refer to the MON2000 Software for Gas Chromatographs User Manual P N 3 900 522 for BOS upgrade details Optional boards may be plugged directly into the PC 104 Bus connectors 19 and J20 on the CPU board assembly The COMAA Board provides four additional serial ports COMS through COME Modem board and Ethernet board can also be plugged directl
29. 3 43 Model 500 Gas Chromatograph Table 3 3 Direct Serial Connect Cable PIN 3 2350 068 Pin number of fhe female DI Slug Connect exposed lends to one of GC Function 5 Controller RS 232 serial conum P Yes Exposed lead goris on Terminal Board FB for Serial port E Bela wiring IS 6 210 or Ji 1 pin number 9 m mur Ed EDIE T DCD RISD snam e white 2 SOUT CSD Sour 3 black SIN quy J sas xm Lm Os D Tam Still another option is to fabricate a serial cable and its plug ends by following guidelines provided in Appendix A this manual PC to GC Long Distance with RS 422 or RS 485 RS 422 and RS 485 serial protocols are recommended for longer distance serial connections between the PC and GC System G e distances greater than the 50 feet To connect a PC to one of the GC Controller s internal serial port jacks that accept RS 422 or RS 485 serial protocol proceed as follows 1 Obtain the following equipment asynchronous line driver interface device with RS 232 input and RS 422 or RS 485 output See Appendix A this manual for example brand and model Shielded computer grade twisted pair cable to connect the asynchronous line driver device to the GC 2010 Controller PC Wiring Serial Connections 3 44 gt Installation and Setup Model 500 Gas Chromatagraph A straight through serial cable to conn
30. 3 Streams S C S Plate 4 Streams Flow Configuration Backflush to Measure Dual Column wISSO Wiring 500 Series GC with S C S Plate GC Con troller Analyzer Wiring Diagram 500 Series GC with 5 5 Oven Assembly Valve 6 Port Chromatograph TGP Outline and Dimensional Model 500 G C 5 0 5 Plate Outline and Dimensional Model 500 G C w Explosion Proof and 8 C 8 Plate 5 0 5 Plate 3 Streams with 120 Bypass S C S Plate 4 Streams with 120 Bypass Filters 1 2 Addendum 1 Model 500 Gas Chromatograph CE 24513 5 0 5 Plate 5 Streams w Auto Cal amp Model 120 Bypass Filters JULY 2010 segue Notes m ia AX CONNECTIONS FOR TEMPERATURE MEASUREMENTS rele DEGENTES Gs mee 4 m gt CUSTOMER NOTE TYPE J THERWOCOUPLE MRE ONLY m z BUT SEE n OMR METAL DELE p iei ome AX WRES 3 BLK WHT AND GRN TO BE PIGTAILED IN PI uywa AX WRES 2 WHT AND RED FROM PRESSURE e Ec mere a El met a B meer Ej E m
31. COM m Serial Port 5 COMB P22 Serial Port 6 COMB P23 Serial Port 7 COMD P24 Phoenix plug bare wire connections are available to the first four serial ports Pin outs are identical for all four serial port Phoenix plugs and jacks Each Phoenix plug jack male combination allows bare wire connection and uses 9 pins as illustrated oR 8 cts TRIS 6 DSR 5 GROUND 200 1 RLSD 00D Figure A 1 Phoenix Connector 5 J6 J10 and J11 Pinout DB 9 plug connections available for Serial Ports 1 2 5 6 and 7 GC SERIAL PORT AND CABLE CONFIGURATIONS FOR RS 232 JULY 2010 Supplemental Wiring Guide Serial Communications A 3 Model 500 Gas Chromatograph Four of the serial ports as noted in Table 1 permit connection via DB 9 plug NOTICE PC 10 GC connections direct serial The GC serial ports were wired appear as DCE so straight through serial between the GC Controllo and the PC The PC is Data Terminal Equipment or DTE See Section 2 External modem to GC connections serial A custom serial cab must be built to emulate a null modem cable for a connection between the GC Controller and an external modem The modem is Data Communications Equipment or DCE See Section A Both of the GC Controller s DB 9 jacks are female and have identical pin assignments NOTE A DB 9 male pin numbering scheme is also ill
32. Installation and Line Purging Replacing Carrier Cylinder 8 2 gt Manifold for Two Carrier Gas Bottles to GC System Model 500 Gas Chromatograph B 1 ILLUSTRATION ANALYZER 4 v2 va CARRIER CARRIER CYLINDER CYLINDER 1 2 Figure B 1 Manifold for Two Carrier Gas Bottles to GC System ILLUSTRATION 2010 Model 00 Gas Chromatograph 2 Manifold for Two Carrier Gas Bottles to GC System B 3 INSTALLATION AND LINE PURGING as follows 1 Install manifold as shown in Figure B 1 Close all valves and tighten all fittings Run tubing to Analyzer but do not connect 2 Back off pressure regulator counterclockwise fully 3 Open cylinder valve for Carrier Cylinder 1 The pressure indicator will read the cylinder pressure 4 Open the shut off valve attached to the carrier regulator 5 Regulate pressure out of the cylinder to 20 psig then close the cylinder valve 6 Open V 1 bleed valvo and let the carrier gas bleed to atmosphere until both gauges read 0 psig then close V 1 7 Repeat steps 4 and 5 two more times to purge the line to V 2 8 Purge the line to V 3 by repeating steps 2 through 6 but this time use bleed valve V 4 and Carrier Cylinder 2 9 With valves 1 4 closed open both eylinder valves and regulate both carriers to approximately 10 psig 10 Open V 2 and V 3 simultaneously then turn both eylinder valves off and let the carrier gasses bleed thro
33. Termination Board with jackpost assemblies h Install the DB9 connector from COM to P24 on the Field Termination Board with jackpost assemblies G Install the ten position connector from COMB to J12 on the System Interface Board Connect the Analog cable to J6 on the System Interface Board Refer to Section 3 4 4 1 for port configuration RS 232 RS 422 and RS 485 and pin outs amp With COM4A Boards installed Serial Port 8 is usually assigned via MON2000 Application gt Serial Ports menu path Select Front Panel from the Usage pull down menu see Figure G 6 and G 7 below Figure G 8 MON2000 Serial Port 8 Front Panel Configuration with COM4A Board Installed uiv 2010 The COMMA Board G 12 gt 2350 to 2350A CPU Retrofit Instructions Model 500 Gas Chromatagraph Figure G 7 MON2000 Serial Port 4 Front Panel Configuration G 5 ADD A MODEM 1 At the GC Controller site remove the Controller enclosure s front panel SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Before removing tho unit cover from the GC Control 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 a For the explosion proof Controller the front panel is secured by 16 screws Remove those screws first b Then carefully lowe
34. and Upper XJT Box inside Decoder Preamplifier Analyzer valve driver and temp controller Analyzer valve switches Flow Panel Lower XIT Box Lower XJT Box Power supply ses _ Terminal board Mounting Sample system valve Plate driver board ANALYZER Figure 2 1 Analyzer Subsystems Physical Description JULY 2010 Equipment description lt 2 7 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 Figure 2 2 Chromatagraph Valve uiv 2010 Chromatograph Vales 28 Equipment description Model 500 Gas Chromatagraph 223 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 NOTICE Actuating Subassemblies Below the primary plate pistons are operated by pneumatie 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
35. 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 EQUIPMENT DAMAGE OR PERSONAL INJURY Do not apply AC electrical power to the Analyzer or the GC signal connections have been been made grounds have 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 1 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 uiv 2010 Point to point Wiring Guido Analyzer Conuolier 326 gt Installation and Setup Model 500 Gas Chromatagraph 3 3 2 Analyzer AC Power Wiring 1 Observe Precautions and Warnings 2 Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring connect 115 volts AC Power to the Analyzer follow these 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 Analyz
36. thus foreing 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 Detector Subsystem The operation of the Analyzer detector subsystem was previously discussed in the Theory of Operation section of this manual Detector Subsystem 2010 Equipment description lt 2 9 Model 500 Gas Chromatograph 2 2 4 Analyzer eamplifior 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 Ambient Temperature Range 18 degrees Celsius C to 55 C 0 F to 130 F
37. 3 31 Model 500 Gas Chromatograph inspeet 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 disconnected Ob in hazardous environment working Failure to observe all safety precautions could result in serious injury or death 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 uiv 2010 Modbus Slave Address COM ID Setup 332 Installation and Setup Model 500 Gas Chromatagraph Figure 3 6 Explosion Proof Controller DIP S 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 Figure 3 7 Right Side View of Rack Mount and Panel Mount Controllers Modbus Slave Address COM 1D Setup JULY 2010 Installation and Setup 3 33 gt 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 mainte
38. 36 gt 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 5 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 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 Route the Analyzer Controller Interconnect Cable appropriately especially in the case of the explosion proof Controller enclosure SIGNALS TO AC POWER ALL OTHER AND FROM SIGNALS ANALYZER Figure 3 9 Seperate Conduit Entries for Cable In Out of GC Controller Controllo Analyzer Wiring JULY 2010 Installation and Setup 3 37 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 34 3 Controller PC Wiring Serial C
39. 5 8 7 8 9 Figure A20 C COM RS 485 Configuration E J16 i To UO Not installed d Not Installec d U11 Not Installed T GND U12 Instales Figure A 21 COM COMS RS 485 Configuration 4 T U4 NotInstalod gr UT Not Installed UB Installed uiv 2010 Jomper sased Serial Channel Configurations A22 gt Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatograph Figure A 22 COMS RS 485 CPU COM4 RS 485 Configuration DBS as am PIN DEFINITIONS i U10 Not installed 1 NA 2 d Not Install 2 Dome gt d U13 Not Installed 2 Dep UM Installed ran 5 GND 8 NA 7 NA 8 NA 9 NA Figure A 28 COME RS 485 Jumper based Serial Channel Configurations uty 2010 APPENDIX B MANIFOLD FOR TWO CARRIER GAS BOTTLES TO GC SYSTEM This Appendix provides a description of a Carrier Gas Manifold that permits connection of two carrier gas bottles or eylinders to a Gas Chromatograph GC System part number for the manifold is 3 5000 050 The benefits of this manifold are as follows When one bottle is nearly empty Le 100 psig remaining the other bottle becomes the primary supply Each bottle can be disconnected for refilling without interrupting GC operation This Appendix is organized as follows Mlustration
40. 7 1 GC Controller Address Change 58 See Modbus Slave Address COM ID Setup on page 3 30 for an explanation of DIP switch settings and their determination of the GC COM ID When the desired GC Controller device address is known it will be set before the Model 500 leaves the factory If the GC Controller device address needs to be changed in the field it will be necessary to change the arrangement of an 8 position DIP switch Refer to Modbus Slave Address COM ID Setup on page 3 30 for the location and arrangement of the DIP switch settings and Figure 3 6 Figure 3 7 and Figure 3 8 The GC Controller address on the DIP switch can be set as a 5 bit binary number with the position marked I as the least significant bit For the switch positions OFF 0 and ON 1 Refer to Modbus Slave Address COM Setup on page 3 30 for more dip switch settings ANALOG INPUTS AND OUTPUTS The analog outputs can be calibrated adjusted using a PC with the MON2000 program software However user output GC Controller analog outputs should be measured with a good digital meter upon initial installation at zero scale and full scale Then the span be set with MON2000 Software from the PC so that it represents values from zero to 100 percent of the user defined units in use Nominally calibration is made within a range of 4 20 milliamperes mA output from each analog channel However zero scale calibr
41. A 10 Example RS 485 Serial Cable Terminations Line Driver to GC Controller COM 1 COMT Table A 3 Jumper and Switch Settings for LD4854 MP Line Driver RS 485 to GC LABEL POSITION PURPOSE Front Panel Switch NORMALT DLE NORMAL Normal operation used instead of loopback DIP Switch Banks or Shunt XWIA DCE XWIB DTE XWiA DCE Sets line driver ta tions equipment DCE E UNTERM No resistor network termination needed for one PC direct to one GC Jumper Positions uiv 2010 EXAMPLE RS 485 CONNECTION FROM PC TO GC Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatograph LABEL POSITION PURPOSE we HALF Half duplex operation wo Oms O zero milliseconds delay from time request to send RTS received true until clear to send CTS asserted as true wis AB RS 455 driver enabled by RT wis AB Half duplex turnaround delay at B 100ms Disable timeout delay by 100m wis EC RS 48 driver enabled by RTS EXAMPLE RS 485 CONNECTION FROM PC TO GC suty 2010 Supplemental Wiring Guide Serial Communications A 15 Model 500 Gas Chromatograph A6 JUMPER BASED SERIAL CHANNEL CONFIGURATIONS The WinSystems CPU PIN LPM MCM 6117 provides four serial channels each of which can be configured to use the RS 232 RS 42 RS 485 protocols with the addition of optional driv
42. ANSI Y14 5 x LATEST REVISION amp S C S PLATE ER E E EMERSON 4 STREAMS WITH T Process Management 120 BYPASS FILTERS APPI DLT PaE 4 30 05 Ents see ORDER 971 OF 1 NOTES ANALYZER OVEN menos Tut sente oj s NT T wene PUT Blum DIU eM ERUNT LEMIG IM TU ust V VAN RES VR es scs PATE AI 5 T amt EMERSON j ine EDP s IEICE CELI war eh mx om mane REI CES Inna Era gt me qaa fear lr e 7 ADDENDUM 2 CONTROLLER DRAWINGS This addendum contains schematics and drawings of the GC Controller portion of the Model 500 Gas Chromatograph System Drawings are listed below in the same page order as found in this addendum BE 18044 BE 20767 CE 18115 CE 18118 CE 20766 CE 21743 CE 21743 001 DE 20775 DE 20778 DE 20779 DE 20780 DE 20781 DE 20782 Assembly Analog Board Assembly Modem Board Assembly Termination Board Sheet 1 of 2 Component Side Sheet 2 of 2 Solder Side Deseript Transient Protect Mod amp Plugs System Interface and Driver Board Assem
43. Address Change 5 2 Maintenance Model 500 Gas Chromatograph Analog Inputs and Outputs Analog Output Dialog Description Changing a Variable Changing the Bargraph Performing a 2350A Manual Calibration Performing a 2350A Automated Calibration Analog Loopback Test Cireuits Upgrading Analog Outputs Discrete Digital Inputs and Outputs Digital Loopback Test Circuit Fuse Protection Analyzer Controller Interconnect Funetion Codes 5 1 TROUBLESHOOTING AND REPAIR CONCEPT The most efficient method for maintaining repairing the Model 500 Analyzer System is based on unit replacement concept that permits returning the system to operation as quickly as possible Sources of trouble such as printed circuit assemblies valves ete are identified during troubleshooting test procedures and are replaced at the lowest level practical with units in known working order The defective elements are then either repaired in the field by reference to the applicable instructions or returned to Emerson Process Management for repair or replacement TROUBLESHOOTING AND REPAIR CONCEPT uty 2010 Model 500 Gas Chromatograph 52 ROUTINE MAINTENANCE The Model 500 Analyzer System will perform accurately for long periods with very little attention However a bi monthly record of certain parameters will assist greatly in assuring that your Analyzer is operating to specifications The Model 500 Maintenance Checklist should be
44. Controller may show a truncated or curtailed version of the displays available at the PC To adjust the contrast and backlighting of the screen while logged out Press these keys NEXT Key Reset contrast and backlighting to default values UPARROW key Increase contrast DOWN ARROW key Decrease contrast LEFT ARROW key Increase backlighting RIGHT ARROW key Decrease backlighting To log out if the Main Menu sereen is displaved Press ESC Keypad The front panel keypad on the Controller is arranged so that the most used keys may be pressed directly These are the numeric keys the ESC NEXT BKSP ENTER period and keys The other keys are obtained by pressing ALT and the desired letter or symbol on the lower half of the key For instance to obtain capital A press ALT while simultaneously pressing the A key To obtain capital B hold down ALT and press B twice Although not shown on the keypad the small letter b may be obtained by holding down ALT and pressing B five times All letters of the alphabet may be obtained by similar actions The other funetions or symbols shown on the lower half of the keys are obtained similarly The numerical keys the period the dash or minus and the Liquid Crystal Display LCD JULY 2010 Model 500 Gas Chromatograph funetion keys Operation trom Local Keypad and Display lt 4 5 used to enter data values or to issue instructions to the Controller Analyzer
45. DEPTH FOR TERMINATION BOARD AND CONNECTOR 11 00 3 10 m 25 P22 P23 P24 me 1 1 13 DISPLAY COMM N DISPLAY POWER 9 8 J Y 7 8 J 12 6 7 J E 5 6 J 10 4 5 9 8 lt 3 4 J e 8 2 3 7 7 6 d7 O ls 1 5 5 10 lt 4 4 3 9 9 lt 3 3 2 8 8 lt 2 2 4 7 7 lt 1 J 1 J Y 5 5 8 9 4 4 4 7 e bs 3 j i j O i 4 5 4 3 4 12 lt 2 3 11 9 lt j 2 8 10 8 J17 1 7 9 7 q 8 6 6 lt 7 5 5 lt 6 4 4 d O 3 gt 2 2 lt 3 1 1 lt J A BACK VIEW 19 00 ALARM STATUS LEDS UNACK ALARM WORKING ACTIVE ALARM EMERSON Controller Process Management 55 la LL ee DEF 4 5 6 HBE oj e aJ x ese HANDLES SERIAL PORT SIDE VIEW FRONT VIEW SI METRIC THIRD ANGLE PROJECTION FINISH s THIS DRAWING IN DESIGN AND DETAIL IS OUR PROPERTY AND MUST NOT BE USED EXCEPT IN CONNECTION WITH OUR WORK IT SHALL NOT BE REPRODUCED AND SHALL BE RETURNED TO US ON DEMAND ALL RIGHTS ARE RESERVED GEOMETRIC TOLERANCES amp DIMENSIONS PER o EST REVISI DIMENSIONAL 2350A LATEST REVISION 19 RACK EMERSON WITH DISPLAY AND KEYBOARD Process Management DATE 1 8 02 DWG NO REV BREAK ALL SHARP CORNERS TQCHKD Ey DATE 1 10 02 D F 20779 B PROJ FILE NO NONE FILENAME DE20778B1 DWG DATE 05 07 04 TIME 1 07 P M
46. ECO XX 157611 EM DLT Process Management A 03 26 02 RD ERO YY 10078 EM DLT PD mn 20775 F N A REV DATE DRN DESCRIPTION CHKD API PROJ FILE NO NONE FILENAME DE20775F1 DWG DATE 12 01 04 TIME 3 18 P M DIT Mr 3 26 02 sce ORDER i OF 6 NOTES N INSTALL GROUND LUGS ITEM 206 IN 3 LOCATIONS FOR DETAILS OF GROUND LUG SEE DRAWING 12688 A CLEAN SURFACE AREAS OF CASE AND COVER WITH 3M ADHESIVE CLEANER P N 9 9960 179 WHERE DECALS ARE TO BE APPLIED INSTALL FIELD WIRING DECAL FROM ITEM 202 ON LEFT SIDE WALL INSTALL GROUND SYMBOLYS ALONG BOTTOM FRONT EDGE INSTRUCTIONS DECAL ON RIGHT SIDE WALL PLACE BRADY LABEL INDICATING REVISION LEVEL OF CPU SOFTWARE IN LOWER RIGHTHAND CORNER BLOCK OF INSTRUCTION DECAL MARK LABEL WITH THE FOLLOWING INFORMATION 8 2350 0 REV CS CLEAN MATING SURFACE WITH ADHESIVE CLEANER P N 9 9960 1789 AND INSTALL 2 DESICCANT BAGS ITEM 412 IN THIS AREA ON BOTTOM OF ENCLOSURE INSTALL CARDCAGE BRACKET ITEM 201 IN CASE BRACKET MUST BE ORIENTED AS FAR DOWN AND TO THE RIGHT AS POSSIBLE TO ALLOW THE CARDCAGE ASSEMBLY TO CENTER CORRECTLY IN THE CASE 4 4 a m D Z o CD m m Z 9 METRIC THIS DRAWING IN DESION AND DETAIL IS OUR PROPERTY AND MUST NOT BE USED EXCEPT IN CONNECTION WITH OUR WORK IT SHALL NOT BE REPRODUCED AND SHALL BE RETURNED TO US ON DEMAND ALL RIGHTS ARE RESERVED THIRD A
47. Figure serial Part 4 Front Panel Configuration GA 2350 OPTIONS The following board configurations are optional for the Model 500 with 2350A Controller G 4 1 The COM4A Board 1 To add four additional communications ports at the GC Controller site remove the Controller enclosure s front panel 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 safety precautions when you are working in hazardous environment Failure to observe all safety precautions could result in serous injury or death a For the explosion proof Controller the front panel is secured by 16 ews Remove those screws first uty 2010 2350A OPTIONS lt G 10 gt 2350 to 2350A CPU Retrofit Instructions Model 500 Gas Chromatagraph 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 e For the rack mount Controller the rear of the enclosure is open it allows access for most field wiring procedures without removing the enclosure 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 3 Loosen the six s
48. 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 and D Rack Size Height 58 inches 147 3 centimeters em Width 18 inches 45 7 em maximum Depth 18 inches 45 7 em Weight Approximately 125 pounds 56 8 kilograms kg including mounting hardware uiv 2010 Analyzer Preamplifier Unit 240 Equipment description Model 500 Gas Chromatagraph 226 23 Sample Requirements Fluid Phase Vapor Pressure 15 to 30 psig regulated to 10 percent Flow Rate 50 cefmin typical Analyzer Output Signal Four difforent gain channels to provide a 4 to 30 mA signal to the Controller Transient Over Voltages Category Installation Category Over Voltage Category ID Cleaning requirements Restricted to the 6 port valve refer to Valve Cleaning on page 5 22 Utility Gas Requirements 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 95 pure helium at 115 psig Consumption is 100ce 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 eylinder since overall gas
49. Lines Purging Calibration Gas Lines System Start up Summary of Installation and Setup Steps 1 Observe Precautions and Warnings See Precautions and Warnings page 3 3 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 Install Analyzer Sample amp 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 Purge Carrier Gas Lines See Purging Carrier Gas Lines on page 80 9 Purge Calibration Lines See Purging Calibration Gas Lines on page 3 83 2010 Model 500 Gas Chromatograph 10 Start Up GC System See System Start Up on page Installation and Setup lt 3 3 3 1 PRECAUTIONS AND WARNINGS The Analyzer and GC Controller when housed inside explosion proof enclosures meet the certifications and classifications identified in Electrica Mechanical Safety and Integrity Certifications and Classifications on page 2 18 Emerson Proc Management does not however accept any responsibilty for installations of these or any attached equipment in which the installation or operation thereof has been performed in a manner that is neg
50. Local Keypad and Display 4 15 Model 500 Gas Chromatograph set the valves and view the Gain Ratio Indicators GRD from the Analyzer Hardware 1 Streams 2 Analog Inputs 3 Analog Outputs 4 Discrete Inputs Discrete Outputs 6 Valves Current GRI Values 4 3 3 Operator Entries Menu The submenus of the OPERATOR ENTRIES menu enable an operator to adjust and refine the entries normally specified in the application as it leaves the factory Modifications may be made in entries from the Component Data Table CDT Retention Times RT Response Factors RF ete for various components and streams These submenus may be used to adjust or define timed events analysis and cycle times for sample streams designate system names and define the calculations desired Names or labels can be specified for data that may be desired for the various reports These submenus allow the operator to refine and customize the applications for the desired usage Operator Entries 1 Component Data 2 Timed Events 3 Analysis Cycle Times 5 Caleulation Control 6 User Defined uiv 2010 Operator Entries Menu 416 Operation trom Local Keypad and Display Model 500 Gas Chromatograph 4 3 4 4 3 5 4 3 6 Alarms Menu The ALARMS menu allows the operator to view set limits and respond to various alarms 2 Discrete Alarms 3 Active Alarms Unackd Alarms Chromatogram Menu The CHR
51. a Te Terminal 4 ier a Terminals Terminal amp T uiv 2010 CPU and COM4A Serial Communications Setups 3 60 gt s Installation and Setup Terminal Hoard for Field Wiring at Controller TE 6 socket COME Terminal 2 23 COME ico Terminala 3 5 a Terminal a 3 Terminal 5 GND Terminal amp Be COM4A RS 485 Configuration Ports Model 500 Gas Chromatagraph Maximum number of RS 485 ports available seven see Section 3 4 5 Controller Printer Wiring on page 69 which are routed to DB 9 plug connections female P2 COMI P3 COM2 P22 COM P23 COM P24 COM Phoenix plug connections or bare wire connections GC Controller TB J5 COMI J6 COM2 J10 COM3 and J11 for RS 485 Voltage Line drivers meet Eleetronies Industries Association EIA specifications for RS 485 Recommended Maximum Cable Length 4000 feet 1219 meters CPU and COMAA Serial Communications Setups ULV 2010 Installation and Setup 3 61 Model 500 Gas Chromatograph outs sans Terminal Hoard for Field Wiring at Controller FB 35 COM Terminal 2 Rex 5 Terminal 3 Ter Terminal 5 GND 310 COM3 yn COMO Terminal Board for Field Wiring at Controller FB P2 COMI Terminal 2 Relic amp Terminal 3 R
52. board If you are using the CSA approved Radicom modem ensure that it is the top card in the card cage assembly The connection configuration of the Radicom modem requires installation at the top of the assembly uiv 2010 TO ADD AN ETHERNET CARD G 18 gt 2350 to 2350A CPU Retrofit Instructions Model 500 Gas Chromatograph This page is intentionally left blank TO ADD AN ETHERNET CARD JULY 2010 APPENDIX H 6117 CPU TO LX 800 CPU UPGRADE INSTRUCTIONS This section describes a procedure for upgrading a Model 500 gas chromatograph with a WinSystems LX 800 CPU board P N 2 3 2 232 The new CPU board is supplied with a retrofitting kit Replacement este guides In addition to the new CPU board the kit contains the following items MON2000 Gas Chromatograph Software for Windows PIN 2 3 2350 400 This CD ROM also contains the software s user manual P N 3 9000 522 Six replacement cables A 5 Amp replacement fuse P N 2 5 4203 130 Two replacement card guides P N 2 4 5001 078 2 8117 CPU to LX 800 CPU Upgrade Instructions Model 500 Gas Chromatograph In some cases when retrofitting the new CPU card it may be necessary to also retrofit the analog board For more information see Retrofitting the Analog Board on page H 11 INTRODUCTION 1 i amp The LX 800 CPU assembly has been designed to include all digital 1 0 and COMI through serial port
53. chassis ground Toop of extra cable left for service purposes inside the GC Controller explosion proof housing must be placed near the conduit entry for AC power If the above precaution is not folo ta and from the GC Controller can be adver 3 1 4 Electrical and Signal Ground ome ouem Warnings Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring Follow these general precautions for grounding electrical and ignal 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 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 suty 2010 Installation and Setup 3 9 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 Aclamp type ground lug is located on the outside of the GC Controller s case at the rear of the lower right facing the o
54. 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 A detector located at the outlet of the analytieal 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 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 comparcd contrasted with a current or another stored chromatogram This could be of great assistance when changing parameters or isolating a problem FUNCTIONAL DESCRIPTION uiv 2010 Description lt 1 5 3 Model 500 Gas Chromatograph Use of a PC for configuration and troubleshooting procedures is essential most instances Basic operations can also be performed from a keypad and liquid erystal display that are built into certa
55. consumption is minimal 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 uiv 2010 Equipment description lt 2 11 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 explosion proof hazardous environment GC Controller package The local alphanumeric keypad and display allow for maintenance and minor adjustments in a hazardous environment SERI
56. enter Username PIN IN x prompt does not pressed the ENTER key press the ESC Key and then pres ENTER key again If the Enter 3 Enter your Username and Personal Identification Number PIN if necessary and then press the ENTER key If you have a PIN number assigned you only have to enter the PIN This allows the Main Menu to be shown on the screen see Section 4 3 1 Main Menu on page 14 for an illustration The super user assigns pin numbers and user read write access permission from the MON2000 Software program 4 From the Main Menu press the number of the menu desired or use the DOWN or UP ARROW keys to highlight the menu desired then press the ENTER key 423 Start Halt an Auto Sequence Analysis start an auto sequence analysis proceed as follows 1 In the Main Menu sereen press the 5 key to select GC Control Start J Halt an Auto Sequence Analysis uiv 2010 Operation from Local Keypad and Display lt 4 9 Model 500 Gas Chromatograph 2 In the GC Control submenu screen press the 1 key to select Auto 3 At the Auto Purge prompt either a Press the ESC key to accept the default Yes option or b Toggle the default Yes option to No by pressing the ALT SPACE keys then press the ESC key Auto Purge allows sample gas to flow through the sample loop for 0 seconds prior to the beginning of the first analysis cycle 4 At the Write Changes prompt pr
57. filled in bi monthly dated and kept on file for access by maintenance technicians as necessary See next page This gives you a historical record of the operation of your Analyzer enables a maintenance technician to schedule replacement of gas cylinders at a convenient time and allows quick troubleshooting and repair when it becomes necessary A chromatogram a configuration report and raw data report should also be made and filed with the checklist furnishing a positive dated record of the Analyzer The chromatogram and reports will also prove valuable in comparison with the chromatograms and reports run during troubleshooting Copy the Model 500 Maintenance Checklist next page as necessary for your files If you have a problem please complete the checklist and reports and have the results available when calling Daniel Measurement Services DMS a division of Emerson Process Management with a problem Also have the Sales Order number when calling The Sales Order number can be found on the corner of the upper electronics housing of the Analyzer The chromatograms and reports archived when your Analyzer left the factory are filed by this number i e HE sccxxx or XXXXX Two numbers may be found Record both One is the sales order number The other is the serial number uiv 2010 ROUTINE MAINTENANCE 5 4 Maintenance 5 2 1 Model 500 Maintenance Checklist Date Performed Model 500 Gas Chromatagraph Sales Ord
58. ineh Back Mounted Version uiv 2010 Controller Hardware Configurations 214 Equipment description Model 500 Gas Chromatograph EMERSON Process Management vet Ou E E 1 nox tg Figure 2 5 Model 2251 Retrofit Kit 12 inch rach 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 uiv 2010 Equipment description 2 15 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 ean be consistently routed However the 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
59. interface allowing much longer cable runs than possible than with RS 232 The differential transmitter and receiver twisted pairs offer a higher degree of noise immunity The following illustrations show the correct jumpering driver IC installation and UO connector pin definitions for each of the COM4 channels when used in RS 422 mode DB9 as am PIN DEFINITIONS 3 U10 Not Installed 1 NA Eo U13 Installed HE U14 Installed 5 GND IRX B NA 9 Figure A 19 COME RS 422 CPU RS 485 Configur The RS 485 multi drop interface is supported on all serial channels with the installation of the optional Chip Kit P N 3 2350 115 A single kit is sufficient to configure two of the channels for RS 485 RS 485 is 2 wire multi drop interface where only one station at a time talks transmits while all others listen receive The following illustrations show the correct jumpering driver IC installation and 70 connector pin out for each of the COMI channels when used in RS 485 mode Jumper based Serial Channel Configurations 2010 Supplemental Wiring Guide Serial Communications A 21 Model 500 Gas Chromatograph COMI RS 485 Configuration COM DBS am PIN DEFINITIONS T Ts U2 Not Installed b 2 US Not Installed Bo Bl U6 Installed NA TXenxe GND 1 2 5 4 5 8 NA T H 9 come DBS PIN DEFINITIONS 1 2 3 i
60. 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 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 PREPARATION 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 ion 2010 Model 500 Gas Chromatograph 2 2 Si Installation and Setup 3 13 Selection 1 Observe Precautions and Warnings 2 Plan Site Location Obtain 8 pplies and Tools Install Analyzer Wiring Follow these guidelines for site selection 1 Provide adequate access space for performing maintenance and adjustments a Allow a minimum of 16 inches 41 em in front for enclosure opening and access b Allow a minimum of 15 inches 38 em 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 awa
61. one display ALT and DECR keys suy 2010 Keypad Operation trom Local Keypad and Display Model 500 Gas Chromatograph Backspace B Deletes the character before the cursar position Delete DED Deletes the character at the cursor position ALT and DEL keys Space SPACE Alis a space oris used to toggle lists AUT and SPACE keys Lower Function Shifts the keys marked with a lower function legend into normal aun mode for data entering monitoring operation requirements Use by pressing ALT and the desired function key Alphabet Press and hold AUT key with any desired letter of the alphabet Upper ease letters are entered by pressing 1 2 o 3 times in order and lower ease letters by pressing 4 5 oF 6 times in same order 42 424 LOGGING ON TO VIEW OR EDIT DATA First Time Log On log on the first time proceed as follows 1 Press the ENTER key to display the login prompt 2 in the letters for your username then press the ENTER key VERY IMPORTANT Each new Model 500 GC unit is shipped with Super user named EMERSON downloaded into its memory Therefore for the first log on to new GC unit enter the USERNAME EMERSON To enter the username EMERSON do the following 1 Type in E by pressing and holding tho BB key prossing the key toin then ralonning the koy LOGGING ON TO VIEW OR EDIT DATA uiv 2010 Model 0
62. or Spy Receive data or signal in a serial port pin assignment TxD TD or Sour Transmit data or signal out a serial port pin assignment uiv 2010 GLOSSARY 118 gt Description Model 500 Gas Chromatograph This page is intentionally left blank GLOSSARY suty 2010 EQUIPMENT DESCRIPTION 24 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 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 22 Equipment description Model 500 Gas Chromatagraph 244 242 conditioned that is compatible with chromatograph sample re
63. or other approved vapor tight conduit fittings Electrical Conduit uty 2010 Installation and Setup 3 11 Model 500 Gas Chromatograph EQUIPMENT DAMAGE OR PERSONAL INJURY Consult your company s policies and procedures and oth 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 Observe Precautions nd 2 Warnings 2 Plan Site Location Obtain Supplies and Toots a fossil Analyser Wiring Observe the following guidelines for installing GC sample ystems Sample Line Length If possible avoid long sample lines In ease of a long sample line flow velocity ean be increased by decreasing downstream pressure and using by pass flow via a speed loop Sample Line Tubi g 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 uiv 2010 Sample Systems Requirements Model 500 Gas Chromatograph 32 324 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
64. racks The pin out for the two connectors are shown in Figure 3 23 uiv 2010 CPU and Serial Communications Setups 3 68 gt Installation and Setup Parallel VO Connectors Model 500 Gas Chromatograph The 48 lines of parallel I O are terminated through two 50 pin connectors at J7 and J4 The J7 connector handles ports 0 2 while J4 handles ports 3 5 The pin definitions for J7 and J4 are shown here 1557 co 3004 GND Sooe ND 7908 END 09910 GND 10512 GAD 150516 SAD 70518 AD 190520 1552 SNo 230026 GND 50026 END 270028 END 45930 END 512032 GND 22093 GND 500 GND 372038 GND 55040 GND ood SNo 41554 SNo 50046 GND reese SNo 455 GND Figure 3 23 Parallel 1 0 Connectors J7 and J4 Parallel VO Enable The 1 0 connectors ean provide volts to an rack or for miscellaneous purposes by jumpering J2 When J2 is jumpered 5 volts are provided at pin 49 of both J4 and J7 It the user s responsibility to limit current to a safe value less than 1 to avoid damaging the CPU board The jumper definitions for J2 are shown here E En c A CPU and COMAA Serial Communications Setups JULY 2010 Installation and Setup 3 89 Model 500 Gas Chromatograph Figure 2 4 1 0 VCC Enable 3 4 5 Controller Printer Wi Imam Analyzer Wiring Instat Analyzer Sample amp
65. skip this section and proceed to the 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 suty 2010 Installation and Setup 3 19 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 Lower d ANALYZER Figure 3 2 Lower Esplosion 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 uiv 2010 Pointto point Wiring Guide Analyzer Controller 320 gt Installation and Setup Model 500 Gas Chromatagraph b Maximum length of Interconnect Cable or the maximum distance between the Analyzer and the GC Controller should not exceed 2000 feet 610 meters LOWER XUT ELECTRONCS HOUSING ea Figure 3 3 Behind t
66. source for the 4 20 mA circuit See drawing CE 18118 for an ustration of the System Interface and Driver board Also see Figure 2 6 which illustrates through a block diagram the funetion and placement of the GC Controller circuit boards uiv 2010 Controller Hardware Configurations 2 24 Equipment description Model 500 Gas Chromatograph pas a Figure 2 6 Block Diagram of the GC Controller Circuit Boards Controller Hardware Configurations uiv 2010 Equipment description 2 25 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 built in 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 NOTICE For details on using the Controller s builtin keypad and LCD see Operation from Local Keypad and Display
67. stream switching assembly AC or DC solenoid systems has provisione for eight stream routes but adding this option has the net effect of adding only seven more stream routes the standard stream capacity of five thus giving a total stream capacity of twelve The reason is of the Analyzer standard ive stream routes becomes dedicated to the optional stream switch sembly when the optional stream switch assembly is General Controller Specifications Power requirements without current outputs 63 basic instrument typical for Voltage options n5VAC 280 VAC 15 percent 50 to 60 Hz 0 275 A 5 percent 50 to 60 Hz 0 33 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 uiv 2010 Controller Hardware Configurations 2 18 Equipment description Model 500 Gas Chromatagraph Explosion proof NEMA 4X Groups B 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 ineluding stand Ele
68. the holding screws Do not disconnect the Valve Driver board from the cable merely let the board rest face down secured by the cable 4 Locate the two Type J thermocouples They are in the left side of the housing and are marked 1 Detector and 2 Heater Block See Figure 5 5 2010 Temperature Measurements 526 Maintenance Model 500 Gas Chromatagraph The leads 1 and 2 rmocouple Figure 5 5 Thermocouple Leads in Lower Explosion Proof Housing Set the thermometer for a J reading then insert the ends of the two wires marked 1 and measure their temperature Repeat with wire 2 The column heater temperatures should be 80 3 The detector heater reading will be 5 degrees cooler than the column heater with a wider temperature range fluctuation b Do NOT try to adjust these temperatures without consulting Daniel Measurement Services DMS The temperature control board is not field serviceable Ifyou determine that the temperature control board is bad return it to Daniel Measurement Services DMS for replacement Temperature Measurements JULY 2010 Maintenance 5 27 Model 500 Gas Chromatograph 6 Replace the Valve Driver board and the Condulet cover removed in steps 1 through 3 You will need an accurate flow meter Alltech Digital Flow Check Flowmeter or equivalent for this measurement measure the MV vent flow proceed as fol
69. to J6 on the analog board and replace it with the longer ribbon cable that is supplied with the new CPU board 8 The new CPU board requires that low shoulder smooth faced card guides be used to prevent the possibility of damaging components installed near the edge of the CPU board Remove the existing card cage guides in slot 3 by snapping them out from the back side and replace them with the two card guides provided with the new CPU card Slot 3 is the third slot back from the system interface board uiv 2010 Removing the Old CPU Card 6177 CPU to LX B00 CPU Upgrade Instructions Model 500 Gas Chromatograph INSTALLING THE NEW CPU BOARD To install the new CPU board do the following 1 Remove the new CPU board PIN 2 3 2350 232 from its anti static bag Discharge any static build up by touching the grounded of the controller before removing the new CPU card from its protective envelope If applicable transfor all existing PC104 boards and all mounting hardware to the new CPU board 3 The following jumper settings must be changed on the COM4A and modem boards a COMA board Move the jumper from pins 9 and 10 of J10 to pins 23 and 24 b Modem No jumper changes required 4 If new PC104 board s came with the new CPU board install them first See the installation procedure that is supplied with the PC104 board upgrade kit 5 Place the new CPU board into the card cage s slot
70. to approximately 50 cubic centimeters per minute cc min by adjusting the metering valve on the Flow Panel 14 Prepare for normal operation as follows a On the Valve Driver board lower XJT box reset the Stream switch S2 to AUTO if Stream 2 will be used for calibration gas 5 Close both XJT boxes Figure 3 30 Analyser Valve Driver Board in lower exploion proof housing Purging Calibration Gas Lines suty 2010 Installation and Setup 3 85 Model 500 Gas Chromatograph 3 6 SYSTEM START UP form Leak Checks a Purse Carrier Gas Lines 9 Purge Calibration Lines 10 StartUp GC System To perform system start up follow these steps 1 For system start up run an analysis of the calibration gas Ensure that the Stream switeh for the calibration gas has been set to AUTO see last step previous section 2 Run the GC System in Single Stream mode To operate the GC System with a PC and the MON2000 Software refer to the MON2000 Software for Gas Chromatographs User Manual P N 3 9000 822 operate the GC System from the front panel keypad and LCD refer to Operation from Local Keypad and Display on page 4 1 uiv 2010 System Start Up 3 86 Installation and Setup Model 500 Gas Chromatagraph System Start Up JULY 2010 OPERATION FROM LOCAL KEYPAD AND DISPLAY
71. 0 Gas Chromatograph 422 Operation trom Local Keypad and Display lt 4 7 2 Type in by pressing and holding down the key pressing the OB ey once then releasing the MEM xey 3 Typein E by pressing and holding down the key pressing the B 4 Typein then releasing the key s pressing and holding down the key pressing the E sia MBM rey 5 Type in S by pressing and holding down the key pressing the key once then releasing the key pein O by pressing and holding down the B8 key pressing the koy three times then releasing the ey y pressing and holding down the oy pressing the 1 Typein vey vic then releasing S koy Subsequent Log On For subsequent log on follow these steps 1 If screen saver mode is active i e the screen s backlight is turned off and Emerson is written on the screen in various locations then press any key on the keypad and wait 10 seconds for contrast and backlighting to take effect uiv 2010 Subsequent Log on 4 8 gt Operation from Local Keypad and Display Model 500 Gas Chromatagraph 2 Press the ENTER key A screen similar to the following should be displayed see Figure 4 3 Emerson Series 2350A GasChromatoeraph Detector 1 gt Tdle Stream 0 Run 0 Any 235 24d Enter PIN k MON2000 May 16 07 09 10 1994 Alarm unackd Figure 43 Prose the ENTER key then
72. 0 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 uiv 2010 The Analyzer Detector 1 10 gt Description Model 500 Gas Chromatagraph 1 5 2 Data Acquisition Every second exactly 40 equi spaced data samples are taken for analysis by the GC Controller 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 Asa 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
73. 01 reserve analog output number 1 rt row for the variable Bargraph Variables Type of GC analysis data on which to base signal level of analog output Name of stream monitored by this output lt Camponent gt Name of component monitored by this output Current Value gt Current readout values of the analog output values reflect seale assignments poem Value used to represent the minimum value mA when scaling the analog output value Ws ae Value used to represent the maximum value 20mA when scaling the analog output value pr Analog output operation mode Fixed fixed Ifthe operation mode is fixed the analog output is set to the number entered for the Fixed Value Fixed Values Analog output value used during fixed operation Loro Adjustment Value used to correct Zero S ade Pull Adjustments Value used to correct Full Scale 3 Click on the OK button to accept your changes and return to the main window 4 Click on the CANCEL button to abort and return to the main window uiv 2010 Analog Output Dialog Description 5 34 gt gt Maintenance Model 500 Gas Chromatagraph When defining new analog output perform a calibration first to obtain accurate Zero and Full Adjustment values see Section 5 8 4 or Section 5 8 5 5 8 2 Changing a Variable To change a variable assignment click on the appropriate Vari
74. 1 Gas Chromatograph GC Controller with a 2350A GC Controller To help you with the GC Controller replacement operation this appendix ineludes wiring diagrams and step by step instructions Check off each step as you complete it and fill out the wire color charta in the wiring diagrams This appendix is organized as follows Halt Current Analysis and Power Down Note Existing Wiring Connections to 2251 GC Controller r and Reconnect POSSIBLE EQUIPMENT DAMAGE Remove Cables Replace Controll Carefully read the following instalation procedures BEFORE attempting to upgrade the 2251 GC Controller with a new 2350A GC Controller Failure to follow these instructions exactly may result in damage to the GC Controller Analyzer or peripheral dev HALT CURRENT ANALYSIS AND POWER DOWN To prepare the 2251 GC Controller for disassembly follow these Steps 1 Halt the current analysis Press the RUN key on the 2251 and then press the YES key when prompted to stop the analysis 1 reads FUNCTION proceed to step 2 When the display on the 2 Turn the power OFF to the 2251 The power switch is located on the top of the power supply on the back of the 2251 The 2251 display should be blank when the power is off F 2 gt Upgrading from 2251 to 2350A GC Controller Model 500 Gas Chromatograph 3 Disconnect the AC power cord to the 2251 power supply from the AC outlet SERIOUS PERSONAL IN
75. 10 This provides access to COM3 on J10 and on J11 of the Field Termination Board The serial port setup for in MON2000 must be set as a PC port CPU and COMA Serial Communications Setups JULY 2010 Installation and Setup 3 51 Model 500 Gas Chromatograph For a system with a keyboard and display connect cable P N 3 2350 087 from CPU J6 to the System Interface Board at J8 and J12 This provides access to COM3 on J10 and is dedicated for use as a serial interface to the keyboard and display will not be available at J11 of the Field Termination Board The serial port setup for in MON2000 must be set as a Front Panel covspco 1537 cows ose COM RX COMIX CONSCI COMSDTR 7998 COMS RI b 890 0 Nie BED 179012 Sov OSR olent 399 14 Cova RIS Coma Tx 126016 COMETS 125918 GOMARI GND 190020 Nic COM4A RS 232 RS 422 RS 485 Configuration To configure the PCM COMAA Board for the desired mode of operation use the following information Each of the four serial channels may be configured independently for er RS 232 RS 422 or RS 485 signal levels An optional chip kit PIN 350 115 is necessary to allow configuration of a single channel for RS 422 use or up two channels of RS 485 usage If four channels of RS 422 use is desired four P N 3 2350 115 kits will be required Configuration of ea
76. 104 connector Juy 2010 Introduction 6117 CPU to LX B00 CPU Upgrade Instructions Model 500 Gas Chromatagraph 2 REMOVING THE OLD CPU CARD remove the old CPU do the following 1 For explosion proof controllers do the following a Detach the front panel by removing the sixteen serews that hold it in place b Loosen the six thumb screws that secure the field termination board to the card cage and remove the field termination board c Loosen the four thumb serews that secure the eard cage to the housing and remove the card cage 2 For rack mounted controllers loosen the four thumb screws that Secure the card cage to the housing and remove the card cage 3 The system interface board which has all the ribbon cables and connectors is mounted on top of the card cage For easy access to all the eables and boards in the eard eage set the card assembly down on a flat surface in the upright position with the power supply end down and the system interface board to the right 4 If present remove the analog cables from the J5 and J6 connectors on the system interface board Removing the Old CPU Card uiv 2010 6117 CPU to LX 800 CPU Upgrade Instructions CHS Model 500 Gas Chromatograph 5 Remove all other cables that connect the system interface board to the CPU board 6 Remove the old CPU and analog board from the eard cage 7 Discard the old ribbon cable connected
77. 120VAC 54205230 Inline filter element Nupro 1500 13 1 Electrical and Mechanical Assemblies Analyzer JULY 2010 Recommended Spare Parts 6 3 Model 500 Gas Chromatograph 6 2 GC CONTROLLER SPARES 6 2 1 Printed Circuit Card Assemblies GC Controller Description Part Number CPU Board No 2 2250190 Analog UO board No 5 n channel Analog UO board No optional 32350 039 10 channel Analog UO board No 5 optional 3235034 System interface and driver board 32350 005 Passive termination board 32350 001 Transient suppressor modules optional PCA Quad Sngl 32350 002 PCA Quad DIFF 32250 003 PCA RS 232 Sngl 32350 027 PCA Hi Pwr Discrete Output 32350 019 LED display board explosion proof NEMA 4X Claas Cand Dunit 3 2350 026 6 2 2 Electrical and Mechanical Components GC Controller Deseription Part Number Maximum Minimum 115 230 VAC power supply 3 2 1 1 Fuse 250 VAC 2A 5x 20 mm _ 544203420 5 1 2010 CONTROLLER SPARES 8 4 gt Recommended Spare Parts Model 500 Gas Chromatograph This page is intentionally left blank Electrical and Mechanical Components GC Controller JULY 2010 APPENDIX A SUPPLEMENTAL WIRING GUIDE SERIAL COMMUNICATIONS This Appendix provides additional information about wiring and interfaces for serial transmissions between the Analyzer System and attached equipment i e a PC a mo
78. 3 where the smooth faced card guides were installed To allow the CPU board to move freely up and down in the card cage as the cables are plugged into the headers on the CPU do not plug the CPU board fully into the connector on the back plane board at this time 6 Install the eables on the CPU board in the following sequence a Plug the end of the digital I O cable P N 3 2350 081 Rev C labeled INTF J2 into the system interface board s J2 connector plug the other end of the digital UO cable into the CPU board s J7 connector Installing the New CPU Board uiv 2010 8117 CPU to LX 800 CPU Upgrade Instructions gt Model 500 Gas Chromatograph b Plug the end of the digital I O cable P N 3 2350 080 Rev C labeled INT J3 into the system interface board s J3 connector plug the other end of the digital I O cable into the CPU board s J4 connector c Plug the printer COM1 COM2 cable PIN 3 2350 083 Rev E into the CPU board s J2 connector which is located at the top of the CPU board Plug the 26 pin printer connector labeled INTF J4 into the System Interface Board s J4 connector e Plug the 10 pin connector labeled INTFJ11 into the System Interface Board s J11 connector 9 Plug the 10 pin COMI connector labeled INTFJ9 into the System Interface Board s J9 connector 7 Ifa board was installed and you want to install a keyboard and display go to Installing a Keyboard and Display with COMA
79. 6 a Jumper terminals 4 and 6 common on JT Discrete Digital VO Wiring JULY 2010 Installation and Setup 3 73 Model 500 Gas Chromatograph b To enable digital input apply either 12 or 24 volts DC to terminal 5 on JT 12 volta DC is available from the GC Controller s power supply by jumpering terminal 2 to terminal 5 see NOTICE below and Figure 3 26 24 volts DC is NOT available from the GC Controller s power supply it must be obtained from an external power supply spe pc musta REUS TO ORC 38 7 ExT yOLTAQE common SORS EE s E kw gcn pane as zum coNTROLLEA common Figure 3 26 Digital Input Jumper Wire Connections minal 2 to terminal 5 for 12 volts DC power to input is now done at the factory You should not connection for a GC Controller that Jumpering enable digite have to make this jumper was built after March 1996 uiv 2010 Discrete Digital VO Wiring 2 74 gt Installation and Setup Model 500 Gas Chromatagraph For high current digital output also install a special transient protection module TPM PIN 3 2350 019 in TPM socket 8 Terminal Board for Field Wiring rear side of board See Appendix for TPM details Also move jumper JP1 on the System Interface Board CE 18118 from centered 12 V to centered 24 V and apply 24 VDC to J13 and 72 14 on the rear side of the Terminal Board for Field Wiring
80. ABLE ITEM 103 FROM J1 ON THE KEYBOARD TO J1 ON THE DISPLAY INSTALL LABEL INSTRUCTING FLANGE FACE CLEANING ON COVER BELOW KEYBOARD AS SHOWN CENTER ALONG BOTTOM EDGE THE LABEL IS TO BE UPSIDE DOWN TOP OF LABEL IS ALONG CAST SURFACE EDGE AFFIX TIE WRAP BASE TO ENCLOSURE APPROXIMATELY 5 TO THE LEFT OF LABEL gt gt FUSE BOX ITEM 123 TO INSIDE COVER NEXT TO KEYBOARD AND CENTERED HINGE OF BOX BE AT BOTTOM PUT QTY 5 FUSES ITEM 122 IN BOX PUT SERIAL PORT IC KIT ITEM 43 1 4 ABOVE FUSE BOX AS SHOWN HINGE OF BOX TO BE AT BOTTOM 6 1L AO INSTALL FCC LABEL ITEM 414 ON THE TOP SIDE OF THE COVER P Q RJ DEL J 108 CLEAN SURFACE WITH 3M ADHESIVE CLEANER P N 9 9960 179 EFORE CENTERING LABEL I Ea N FOR DETAIL OF PUSH BUTTON RETURN SPRING SEE DRAWING AE 12659 E f 1 EMERSON O Process Management DO NOT OPEN ewHILE EXPLOSIVE REF REF SI METRIC THIS DRAWING IN DESIGN AND DETAIL OUR PROPERTY AND MUST NOT BE USED EXCEPT IN CONNECTION WITH OUR WORK IT SHALL NOT BE REPRODUCED AND SHALL BE RETURNED TO US ON DEMAND ALL RIGHTS ARE RESERVED THIRD ANGLE PROJECTION F 12 2 04 DIT ECO XX 5000336 EM DLT mamas E E 6 8 04 DLT ECO XX 203411 EM DLT MS TTE N LATEST REVISION D Set mL kd ASSEMBLY 2350A CONTROLLER xui C 10 31 02 RD EC0 XX 158738 EM DLT EMERSON N A 10 11 02 RD
81. ALE HINGE HALVES GO ON ENCLOSURE WITH STUD TOWARD THE LEFT AND FEMALE HINGE HALVES GO ON LID INSTALL COTTER PIN 409 IN EITHER HINGE PIN HOLE AND BEND REF SHEET 1 ALIGN NAMEPLATE ITEM 401 WITH HOLES AND FASTEN WITH DRIVE RIVETS ITEM 405 BOTTOM OF LABEL WILL BE ALONG OPENING OF CASE A INSTALL CABLE ITEM 406 DISPLAY J3 TO T B J1 AND CABLE ITEM 407 DISPLAY J4 TO T B J2 TIE THE TWO CABLES TOGETHER WITH CABLE TIES USE CABLE TIES ITEM 403 AND CABLE TIE MOUNTS ITEM 404 TO SECURE RIBBON CABLES TO COVER AND CASE INSTALL 2 BOLTS ITEM 411 IN EACH TOP CORNER LOCATION TO SECURE COVER CUSTOMER TO INSTALL OTHER BOLTS FROM KIT WHEN INSTALLED FOR DETAIL OF CASE SECURITY SCREW SEE 5 TAPE INSTALLATION KIT ITEM 410 AND POWER INPUT KIT ITEM 413 USED EXCEPT IN CONNECTION WITH OUR US ON DEMAND ALL RIGHTS ARE RESERVED ASSEMBLY 2350A CONTROLLER REV NOTES A TWO 2 EACH 6 32 SCREWS 6 32 LOCKWASHER NYLON STANDOFF NYLON 6 32 NUTS ARE SUPPLIED WITH COMM BOARD ITEM 504 MODEM BOARD ITEM 503 AND ETHERNET BOARD ITEM 510 TO MOUNT BOARDS ON CPU IF ALL BOARDS ARE IN UNIT THE COM4A BOARD IS THE BOTTOM BOARD NEXT THE MODEM AND THEN THE ETHERNET BOARD 2 ANY ALTERNATIVE BOARDS MUST NOT MATERIALLY ALTER THE ENCLOSURE FREE VOLUME OR POWER CONSUMPTION SEE SHEET 6 FOR ASSEMBLY CPU SIDEVIEW CARD AND CABLE INSTALLATION CABLE ARD ITEM DESCRIPTION FUNCTION ROUTING UMBER PLUG IN
82. 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 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 it damage exists notify your local carrier for fab 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 1713 827 6314 for instructions about receiving replacement parts 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 andlor 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 speci
83. 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 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 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 uiv 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 of The Controller has the capability of 22 digital outputs used as follows 6 Analyzer control 8 driver outputs for DC air solenoids stream swit
84. B110 o A11 AEN MEMR 8120 o A12 SA19 low B130 A13 sats IOR B140 o 14 SA17 DACK3 Bt5o o Ais SA16 DROS Bi8o o 16 SA15 8170 o 17 SA14 o A18 SA13 REFRESH B190 o A19 SAT2 SYSCIK 8200 o A20 SAT ROT 8210 o A21 SA10 IRQ B220 o A22 Sag Ras 8230 o A23 SA8 IRO4 B240 A24 SAT IRO3 8250 o A25 Sas DACK2 B280 o A26 SA5 Figure 3 17 PC Bus Interface 16 bit CPU Board Silicon Disk Configuration The Model 500 GC when installed with a 16 bit CPU board uses the M Systems Disk OnChip DOC device as a Solid State Disk drive This section documents the required hardware configuration for the DiskOnChip device used for the Model 500 Analyzer The Silicon disk array is memory mapped into 32K byte hole at segment E800H and has an UO control register at TECH uiv 2010 CPU and COM4A Serial Communications Setups 3 64 gt Installation and Setup Model 500 Gas Chromatagraph 39 Figure 3 18 Disk Configuration Silicon Disk Mode The Model 500 Analyzer when installed with a 16 bit CPU board uses the M Systems DiskOnChip DOC device The mode is controlled via pins 13 14 on jumper block at J11 as shown here m DOC USAGE CPU and COMAA Serial Communications Setups JULY 2010 Installation and Setup 3 85 Model 500 Gas Chromatograph Figure 3 19 DishOnChip dumper Block Jumpering for DOC
85. CKET WITH UE INSTALLED AND CONNECTOR Jt COAT PER 47429 TERT ave PROIECTE a C E j itn L4 iss EMERSON MODEM BOARD penc caos nr Process Management 2380 CONTROLER a iir at far el se omo meer E aaa ge 20757 EEE E TONE nune DAE 04 28 05 TE 1344 er primi ES P lt rz Fes En 20000000 00500000 2 RS Met comes ne X a eT a rr rt PE Ed e i aes etas ah ure pr E BOARD INSTALL PONER CABLE 10 ON ORCUIF FEIER UE e ire E E 09 Sawo A w een e a omen eof ppo Jot 0500000 IP TAA SIEG Son Rae rae En 00050000000 00000000 EX IER t ER EMERSON COMPONENT SIDE MODEL 2350 ASSEMBLY TERM
86. Communications Setups 3 48 gt Installation and Setup Model 500 Gas Chromatagraph CPU RS 232 RS 422 RS 485 Configurations The WinSystems LX 800 CPU board PIN 2 3 2350 232 provides four serial channels each of which can be set by MON2000 to use the RS RS 422 or RS 485 protocols See the Serial Ports section of the MON2000 Software for Gas Chromatographs manual for more information 32 The WinSystems 6117 CPU board PJN LPM MCM 6117 provides four serial channels each of which can be configured to use the RS 422 or RS 485 protocols with the addition of optional driver IC The 6117 CPU board must set jumpers to configure the serial channels See Jumper based Serial Channel Configurations on page A 15 for more information CPU and COMA Serial Communications Setups Installation and Setup 3 49 Model 500 Gas Chromatograph CPU COM1 COM2 Keyboard and Printer Output Header 1 the keyboard and the printer are terminated at J1 Refer to Multi L O Connector on page 66 and Figure 3 21 for additional information LX 800 CPU COM3 COM4 Output Header COM3 and can be configured two different ways To configure a system without a keyboard and display plug the end of the ribbon cable PIN 3 2350 084 Rev C labeled CPU J6 into the CPU header labeled 16 plug the end of the ribbon cable labeled INTF J10 into the header on the System Interface Board labeled
87. DABSA P Terminal Board Serial ine Driver for field wiring GID TXA TXB RXA RXB 135 36 110 111 8 WC coma ys Ln TR coma cons 6 Rx Com cem htt s anol coms mp Com L A 1 ae P eem Low m 2 i 1Me Figure A 9 Example RS 422 Serial Cable Terminations Line Driver to GC Controller EXAMPLE RS 422 CONNECTION FROM PC TO GC JULY 2010 Supplemental Wiring Guide Serial Communications CA 11 Model 500 Gas Chromatograph See Section 3 4 4 for addtional details about serial communications setups at the GC Controller Table A 2 Jumper and Switch Settings for LDA5A MP Line Driver RS 122 10 GC LABEL POSITION PURPOSE Front Panel Switch NORMAL DLE NORMAL Normal operation used instead of loopback DIP Switch Banks or Shunts XWIA DC WIA DCE TXWIBDTE Sete line driver to aperat as data communica tions equipment DCE No resistor network termination needed for one direct to one GC Jumper Positions Ws HALF Half duplex operation ws ON No delay clear to send CTS always ius wis An RS 455 driver enabled by request to send RTS wis An Half duplex turnaround delay at Be wit 0m Disable timeout delay by 100m Wis DE REAR driver enabled by RTS Juy 2010 EXAMPLE RS 422 CONNECTION FROM PC TO GC aaz Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatagraph EXA
88. DB 9 Port Rs 232 CONNECTION FROM GC CONTROLLER TO PC uiv 2010 Supplemental Wiring Guide Serial Communications A 5 Model 500 Gas Chromatograph A 2 2 DB 9 Serial Port of GC to DB 25 Port of PC make an RS 232 serial connection between one of the DB 9 serial ports of the GC and a PC with DB 25 serial port you may be able to use a straight through serial cable terminated as DB 9 male DB 25 female This will work if the PC has a male DB 25 serial port and its pin assignments are identical to those found on an IBM PC The necessary straight through serial cable can be obtained from most computer products suppliers so custom building a cable normally is not necessary Wiring and signal path are illustrated as follows see Figure ES 5 as cable end T 9 Y 22 R 8 RIS 5 CTS 7 CIS 4 RIS 6 DIR GDR 5 GROUND 7 GROUND 4 DSR 0 DIR 3 RxD Vn 2 KD 3 RxD 1 RLSD DCD 8 RLSD DCD Male D8 9 jack for connecti Female DB 25 plug for connecting Gos seral pat 1o PC s serial port Figure A 4 GC DB 9 Port to PC DB 25 Port uiv 2010 D 9 Serial Port of GC to 08 25 Port of PC A6 Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatagraph A 2 3 Phoenix Plug Port of GC to DB 9 Port of PC make an RS 232 serial connection between
89. E ITEM 354 ON CARDCAGE SECURE WITH MOUNTING HARDWARE ITEMS 359 AND 362 IN EVERY OTHER MOUNTING HOLE AS INDICATED ON ASSEMBLY DRAWING PLUG POWER SUPPLY CABLE ITEM 367 INTO TB2 OF POWER SUPPLY ITEM 351 BEFORE INSTALLING ON CHASSIS WITH MOUNTING HARDWARE ITEMS 360 306 361 368 AND 369 AN IAAL STAI DANA S oo d SSS 6 Q S AAA NAA 2 12 GS INSTALL ADHESIVE MOUNT ITEM 366 ON UPPER PART OF SUPPORT RAIL SECURE POWER CABLE TO MOUNT WITH CABLE TIE ITEM 357 AS INDICATED PLUG BACKPLANE CONNECTOR INTO BACKPLANE ASSEMBLY gt gt Eee THIS PART OF CABLE TO BE WIRED TO INTERFACE BOARD POWER SUPPLY ITEM 2 TERMINATION BOARD WHITE INTERFACE BOARD GREEN POWER CORD SI METRIC THIS DRAWING IN DESIGN AND DETAIL IS OUR PROPERTY AND MUST NOT BE USED EXCEPT IN CONNECTION WITH OUR WORK IT SHALL NOT BE REPRODUCED AND SHALL BE RETURNED TO US ON DEMAND ALL RIGHTS ARE RESERVED THIRD ANGLE PROJECTION Process Management MATERIAL BLOCK N A F 12 2 04 DLT XX 5000336 EM FNSH SHT 6 ADDED AT F REV EE BLOCK N A REV DATE DRN DESCRIPTION CHKD APPD PROJ FILE NO NONE FILENAME DE20775F6 DWG DATE 12 01 04 TIME 3 11 P M PR 1 3 02 mom 3 19 02 DE 20775 DLT PE 3 26 02 Ptwrs ser ORDER _ 6 OF 6 NOTES 1 UNIT IS DESIGNED TO FIT IN A STANDARD 19 WIDE RACK LIN ALLOW 2 75
90. ENANCE OF ANY SELLER PRODUCT REMAINS SOLELY WITH THE PURCHASER AND END USER DANIEL AND THE DANIEL LOGO ARE REGISTERED TRADEMARKS OF DANIEL MEASUREMENT AND CONTROL INC ROSEMOUNT AND THE ROSEMOUNT ANALYTICAL LOGO ARE REGISTERED TRADEMARKS OF ROSEMOUNT ANALYTICAL THE EMERSON LOGO IS A TRADEMARK AND SERVICE MARK OF EMERSON ELECTRIC CO COPYRIGHT 2010 BY DANIEL MEASUREMENT AND CONTROL INC HOUSTON TEXAS usa AI 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 Daniel Measurement and Control Inc Houston Texas U S A WARRANTY 1 LIMITED WARRANTY Subject to the limitations contained in Section 2 herein and except as ly provided herein Daniel Measurement and Control Inc and Rosemount Analytical collecively Seller warrants that the firmware wil 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 dato 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 Ser
91. ETHERNET OPTIONAL ETHERNET J5 JACK EXT CABLE TO J19 J20 ON CPU PLUG IN MODEM J11 JACK EXT CABLE 519 PLUG IN 4 CHANNEL SERIAL 1 0 OPTIONAL TO J19 J20 ON CPU COMM 5 AND 6 COM4A J6 TO FTB P22 AND P23 COMM 7 AND 8 COM4A J3 TO FTB P24 INT BD J12 CPU BOARD DIG 1 0 DIG 1 0 BD COMM 1 2 DTR BD J4 J11 J9 COMM 3 AND 4 BD J10 J8 J8 J12 ANALOG BOARD ANALOG 1 0 2 OUTPUTS ANALOG ANALOG 1 0 6 OUTPUTS ANALOG BD J6 TO INTERFACE BD J6 OR ANALOG BD J5 TO INTERFACE BD J5 515 ANALOG 1 0 10 OUTPUTS O SI METRIC THIRD ANGLE PROJECTION F 12 2 04 DIT ECO XX 5000336 EM DLT E 6 8 04 DLT ECO xx 203411 EM DLT Ny un amp VON 5 ASSEMBLY 2350A CONTROLLER m vers newer mo EMERSON N A 10 11 02 RD ECO XX 157611 EM DLT Process Management A 03 26 02 RD ERO YY 10078 EM DT N A DATE DRN DESCRIPTION CHKD APPD mo pey we Ez DE 20775 PROJ FILE NO NONE FILENAME DE20775F5 DWG DATE 12 01 04 TIME 3 36 P M DLT ME 3 26 02 tNrs ser ORDER S 5 OF 6 V 4 2 NOTES CARDCAGE INDICATED AS EXPLODED DRAWING TO INDICATE DETAIL FOR ADDITIONAL HARDWARE ASSEMBLY APPLY A SMALL AMOUNT OF LOCTITE 222 THREADLOCKER ONTO THREADS OF STANDOFFS ITEMS 355 AND 356 AND ASSEMBLE ONTO CARDCAGE ASSEMBLE HANDLE ITEM 365 ONTO CARDCAGE WITH MOUNTING HARDWARE ITEMS 358 AND 363 INSTALL BACKPLAN
92. EXTERNAL MODEM A 3 1 08 9 Serial Port of GC to DB 25 Port of Modem To make an RS 232 serial connection between one of the DB 9 serial ports of the GC and an external modem with a DB 25 serial port you will need to manufacture a cable The cable will need DB 9 male and DB 25 male plug cable ends as illustrated below see Figure B D ne 22 RI 0 ens rors 5 OTS out Som 5 7 m 6 DSR out SRO 2 no 2D mo out 1 RLsD 0C0 ale DBS jack Male 08 25 plug for connecting for connecting to to external modem seria port GCs serial port Figure A 7 GC DB 9 Port to External Modem DB 25 Port RS 232 CONNECTION FROM GC CONTROLLER TO EXTERNAL MODEM suty 2010 Supplemental Wiring Guide Serial Communications A 9 Model 500 Gas Chromatograph The DB 9 jack on the GC serial port is wired to appear like a Data Communications Equipment DCE Therefore you use a custom null modem type cable as shown at make the connection between the GC and an external modem GC serial ports were wired to appear as DCE so that a straight through serial cable could be used instead of a nul modem cabi tor 4 connection between the GC Controller and the PC whic erminal Equipment IDTEL 3 2 Phoenix Plug Port of GC to DB 25 Port of Modem To make an RS 232 serial connection between one of the Phoenix Plug serial ports of the GC and an external modem w
93. FF OFF OFF OFF RAM CLEAR Dip Switch iteh Positions D Clears RAM when unit powered down ON Keeps RAM when unit powered down OFF Modbus Slave Address COM ID Setup suty 2010 Installation and Setup 3 38 Model 500 Gas Chromatograph 3 4 2 Controller Analyzer Wiring Install Analyzer Wiring Tostall Analyzer Sample amp Gas Lines Install GC Controller Wiring Perform Leak Checks This section applies only to GC prewired the explosion roof system wil already have had the Contrlle Analyzer connections made If your system has already been wired skip this section and proceed to the next section Applicable to the digital and analog lines connecting to the GC Controle including the Analyzer Controler interconnect lines Any loop of extra cable left for service purposes inside the GC Controller explosion roof housing must not be placed near the conduit entry Tor AC power If the above precaution is not followed the data and control signals 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 ave been made as explained earlier in Section 3 3 1 this manual uiv 2010 Convollr Analyzer Wiring 3
94. Function code strobe Terminal 1 Terminal 16 J19 Terminal 5 Terminal 17 Auto Zero AZ 120 Terminal Terminal I8 Preamp gain channel 1 J18 Terminal 1 Terminal 19 Preamp gain channel 2 J18 Terminal 4 Terminal 20 Preamp gain channel 3 Tim Terminal 7 Terminal 21 Preamp gain channel 4 J18 Terminal 10 Terminal 22 Common preamp gain J18 Terminal 11 Terminal 23 Alarm function AF 190 Terminal 3 Connect the interconnect cable SHIELD to one terminal specifically terminal 12 of J18 on the GC Controller TB Pointtc point Wiring Guide Analyzer Controller uiv 2010 Model 500 Gas Chromatograph Installation and Setup 3 23 EQUIPMENT DAMAGE OR PERSONAL INJURY Do not apply AC electrical power to the Analyzer or the GC Controller until electrical power interconnection and external signal connections have been been made Refer to Section 3 1 3 for gen concerning signal wiring Failure to properly connect the GC unit may result in serious equipment damage or personal injury 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 At this time you may also want t
95. Gas Lines Install GC Controller Wiring 7 Perform Leak Checks A printer can be connected directly to the GC Controller at either the Controller parallel printer port or one of the Controller serial ports The type and scheduling of reports produced at the GC Controller printer are then determined by settings made in MON2000 the GC control software run from a PC from Reports Submenu select GC Report Request and or GC Printer Control Only a generic printer driver is used at the GC Controller Better control of printer output is available to the printer at the GC connected PC rather than at the GC Controller See Config Rpt Maint Log Menu on page 4 17 Noto too that a printer connected to the GC Controller should not be operated in a hazardous environment SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Do not operate standard off the shelf printer in a hazardous environment Failure to observe all safety precautions could result in serious injury or death Two sets of instructions are provided in this section one for connecting a printer to the Controllers parallel printer port and one for connecting printer to one of the Controller s serial ports uiv 2010 Controller Printer Wiring 3 70 gt Installation and Setup Model 500 Gas Chromatograph connect a printer to the Controller s parallel printer port follow these steps 1 Access the GC Controller s Terminal Boar
96. H Ts soenan wass megane ANTES ion i S C S PLATE I Swat oem NOTES 1 AL cur ETE 1 8 ANALYZER oven Ve SAMPLE VENT 449 PA LI SOLENOID WIRING FLOW PANEL SA aE TE ANE caen Sasi CAL ST STREAM 4 STREN 1 STREAM 2e m smew 3 mmc m S Z URN e Peas eee E e une pja asna Management me ee me Red I FENCE cu sassa EEE TE r a a Ll em aem ARS RE y NOTES PEE PATE 1 8 scio mee Ra FANE Ge ANALYZER oven SAMPLE VENT a e ex FLOW PANEL sm STREAM S SOLENOID WIRING SIREAN e STREAM 2 bri 55 58 STREAM 3 et LEGEND Les STREAM e Dx sagu RE uw LT TEIGXTIT UITAE amp use n a es BLISS seme ESN i EE I a al T MEM Fas MCN SAMPLE VENT MEASURE VENT CARRIER IN gt y NOTES SAMPLE ibi
97. I O Wiring Controller Power Wiring am ANALYZER LEAK CHECKS AND PURGING FOR FIRST CALIBRATION 3 78 Analyzer Leak Checks Purging Carrier Gas Lines Purging Calibration Gas Lines SYSTEM START UP 385 INTERFACE COMPONENTS FOR LOCAL DATA LOCAL KEYPAD AND DISPLAY AND ENTRY 4a DISPLAY 4 1 1 Light Emitting Diode Led Indicators 4 1 2 Liquid Crystal Display LCD 44 4 1 3 Keypad 44 4 2 LOGGING ON TO VIEW OR EDIT DATA 4 2 1 First Time Log On 4 22 Subsequent Log On 4 23 Start Halt an Auto Sequence Analysis 4 2 4 Editing Procedures 4 10 4 2 8 Validity Checks of Data Entries an 2010 Operation trom Local Kaypad and Display 4 gt TABLE OF CONTENTS Model 500 4 3 LOCAL DISPLAY MENUS 4 3 1 Main Menu 414 4 3 2 Hardware Menu 414 4 3 3 Operator Entries Menu 415 4 3 4 Alarms Menu 4 16 4 3 5 Chromatogram Menu 416 4 3 6 GC Control Menu 416 4 3 7 Data Records Menu 417 4 3 8 Config Apt Maint Log Menu 417 MAINTENANCE 5 1 TROUBLESHOOTING AND REPAIR CONCEPT 5 2 52 ROUTINE MAINTENANCE E 5 2 1 Model 500 Maintenance Checklist 54 5 2 2 Routine Maintenance Procedures 55 5 2 3 Contract Service 55 5 3 LOCATING AND GAINING ACCESS TO EQUIPMENT ELEMENTS 55 5 3 1 Analyzer Electrical Electronic Units 55 5 3 2 Detector Elements Heater Elements Valves and Columns 57 5 4 PRECAUTIONS FOR HANDLING PRINTED CIRCUIT 3 5
98. IDE DOWN TO THE SURFACE OF THE BOARD J2 um e Hest Gere TP1 TP4 TP5 TP6 SOCKETS FOR U6 AND U7 J5 J6 AND 0 EJECTOR TAB ITEM 2 CONFORMAL COAT PER MEP 47429 P BO 55825555555555 AFTER COATING SEAL BASE OF U9 SOCKET WITH RTV 3145 ITEM EH 4 SEAL TOP OF SOCKET WITH TWO 1 X 1 PIECES OF KAPTON ADHESIVE BACKED ITEM 5 B o PART DESCRIPTION COMP CET rrr 3 2350 034 ANALOG 8 IN 12 OUT 05 07 od mH 3 2350 039 PCA ANALOG 8 IN 8 OUT 05 06 3 2350 041 PCA ANALOG 8 IN 4 OUT u5 F 09 02 08 HS THIS ORAWING IN DESIGN AND DETAIL 15 OUR PROPERTY AND MUST NOT BE USED EXCEPT IN CONNECTION WITH OUR WOR IT SMALL NOT BE REPRODUCED AND SHALL BE RETURNED TO US ON DEMAND ALL RIGHTS ARE RESERVED THIRD ANGLE PROJECTION E 15 08 CC mE D 5 3 05 HM tco x sonoris rmt Bock DLT ANSI Y4 amp D 9 5 01 RD ECO XX 124663 DLT d E r c 8 24 00 mess mewe wo EMERSON ANALOG BOARD 8 3 8 99 RD or E Process Management MODEL 2350 A 01 98 RD GCS DATE DN APPD sem comes ro 2 z 11 19 97 erm d GN ENE SNELL e DT BE 18044 F PROJ FILE NO FILENAME BE18044F1 DWG DATE 09 02 08 TIME d us D st mar Po NOTES J2 1 2 3 4 AND J3 7 8 SOLDER SIDE ON PC104 CONNECTORS J4 AND 45 TOP COVER OPENING OF SPEAKER MOUNTED Ub JUMPER STRIPS M2 AND 13 SOCKET WTH US INSTALLED SO
99. INATION aa x TEEPE Bgm CE 18115 RE no WOE CEN S070 DE 03 15 00 1243 AN prom ET D TII 55600000 ooo ooo a o 000000009000 95050005 0000000 150000059 mr 99 99 0000000009 00000900 Os te 1 o o nog e Li SEE TABLE 3 ER EM 3 s zl MB a eH E zi EBE sss 1 E H3 11 umm E T H EARTEN s r3 ru 3 r3 r3 7 1 E1 own er ommo eu ur i EEE EEE 88158188 sjela z ie EH ka i EE s gla alg 2 2 BP k ll HEEEEFE JEEEEEE Me EE EE B k F NOTES N sasa cocina DI Lp
100. IRING GUIDE SERIAL COMMUNICATIONS APPENDIX MANIFOLD FOR TWO CARRIER GAS BOTTLES GC SYSTEM APPENDIX C GUIDE TO TRANSIENT PROTECTION MODULES A2 A24 A22 A23 A24 2 Aa AS AS 2 2 GC SERIAL PORT AND CABLE CONFIGURATIONS FOR RS 232 ie V RS 232 CONNECTION FROM GC CONTROLLER TO POL m DB 9 Serial Port of GC to DB 9 Port of PC A 4 DB 9 Serial Port of GC to DB 25 Port of 5 Phoenix Plug Port of GC to DB 9 Port of PC A 6 Phoenix Plug Port of GC to 08 25 Port of 7 RS 232 CONNECTION FROM GC CONTROLLER TO EXTERNAL MODEM cA DB 9 Serial Port of GC to DB 25 Port of Modem AB Phoenix Plug Port of GC to DB 25 Port of Modem Ag EXAMPLE RS 422 CONNECTION FROM PC TO css A AO EXAMPLE RS 485 CONNECTION FROM PC TO e A AZ JUMPER BASED SERIAL CHANNEL CONFIGURATIONS AB ILLUSTRATION B2 INSTALLATION AND LINE PURGING REPLACING CARRIER CYLINDER PURPOSE OF THE TRANSIENT PROTECTION MODULES PART APPLICATIONS NUMBERS AND DESCRIPTIONS Appendix A Supplemental Wiring Guide Serial Communications JULv 2010 Model 500 TABLE OF CONTENTS 7 TROUBLESHOOTING TRANSIENT PROTECTION MODULES n APPENDIX D INTERNAL MODEM FOR GC CONTROLLER APPENDIX E SETTING SOLENOID PURGE FLOWS APPENDIX F F 1 HALT CU
101. 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 PIN 3 9000 522 Modes of operation 2010 Description lt 1 7 Model 500 Gas Chromatograph 15 154 THEORY OF OPERATION GLOSSARY on page 16 for definitions of some of the terminology used in the following explanations The Analyzer Detector The Analyzer detector subsystem is a thermal conductivity detector that consists of a balanced bridge network with heat sensitive thormistors 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 schematic diagram of the thermal conductivity detector is shown in Figure 1 2 uiv 2010 Theory of operation 1 8 Description Model 500 Gas Chromatograph T RENS UPPER ss OF ANALYZER H lt U f Ferran s EL suu ERE EI nere emat lectus nous sa Figure 1 2 Schematie Diagram of Analyzer Det tor 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 ba
102. J10 for access to serial port 4 on the field termination board plug the end labeled INTF J8 into the header on the System Interface Board labeled J8 for access to serial port 3 on the field termination board For a system with a keyboard and display do the following 1 Connect the 20 pin ribbon cable P N connector on the CPU board 2 Plug the 10 pin connector labeled INTF J12 into the header labeled J12 on the system interface board for the serial port interface to the keyboard and display 3 Plug the 10 pin connector labeled INTF J8 into header labeled 28 on the system interface board for the interface to serial port 3 This will provide access to the COM3 port on the field termination board is now dedicated for use as the serial port interface to the keyboard and display 0 087 Rev C to the J6 uiv 2010 CPU and Serial Communications Setups 350 gt Installation and Setup Model 500 Gas Chromatagraph 4 Start MON2000 and do the following a Select Serial Ports from the Application menu b Set the Usage for serial port 4 to Front Panel e Click OK mode RS 232 RS 422 or RS 485 for all four ports can be through MON2000 16 bit CPU COM3 COM4 Output Head COMS and can be configured two different ways To configure a system without a keyboard and display connect cable P N 3 2350 084 from CPU J6 to the System Interface Board J8 and J
103. JURY OR DEATH POSSIBLE Before removing the unit cover from the 2251 make certain th power supply switch is OFF and the AC power cord is disconnected Failure to observe all safety precautions could result in serious injury or death 4 Remove the 2251 power supply from the back of the Controller by loosening the thumb serew lowering the power supply and disconnecting the square power supply connector from the Controller F2 NOTE EXISTING WIRING CONNECTIONS TO 2251 Before disconnecting any wires first record existing wiring connections to the 2251 1 Locate the multi pair interconnect cable that runs from the 2251 Controller to the Analyzer At the cable s termination at the 2251 make note of each individual wire s connection and wire color Record the colors of each of the individual interconnect wires by filling out the color box in the wiring guide next page see Figure 1 remely important Be careful to complete the replacement wiring color box accurately shown in Figure 71 Do not remove any wires at this time NOTE EXISTING WIRING CONNECTIONS TO 2251 uiv 2010 Upgrading from 2251 10 2350A GC Controller Model 500 Gas Chromatograph Mode 23808 G Ana Mode 2251 explosion For Helium electronics 22 53 Figure F 1 GC Controller 22514023504 Replacement Wiring Guide 2010 N
104. LES JUL 2010 Model 500 Gas Chromatograph Guide to Transient Protection Modules C 5 Table Troubleshooting TP PIN 3 2350 002 20 pin Quad Diff Analog UO and Digital UO dow current PIN 2350 003 VISUAL INSPECTION MOVs MIME Good Blue in color Failed Diseolored to brown or black Resistors RTRS Good Intact Failed Broken or open checks EQUIPMENT DAMAGE Remove transient protection module from board before all hmmet Failure to do so may cause equipment damage OHMMETER CHECK MOVs MEMS Open or infinite hms Failed Shorted or 0 ero ohms Resistors RTRS Good 180 ohms Failed Open infinite ohms or short 0 ohms Diodes ZIZ Open infinite ohms in one direction and 4 1 megohms in the opposite direction Failed Short O ohms in any one or both directions JULY 2010 TROUBLESHOOTING TRANSIENT PROTECTION MODULES gt Guide to Transient Protection Modules Table C 4 Troubleshooting TP PIN 32250 004 Model 500 Gas Chromatograph PIN 2300019 20 pin Hi Pwr Discrete Output Digital UO high current VISUAL INSPECTION MOVs 1 Good Blue in color Failed Diseolored to brown or black Resistors RIRS Good Intact Failed Broken or open EQUIPME Remove checks ENT DAMAGE transient protection module from board b
105. MORY REFERENCE 2 5 2350 232 4 ATTACH A BRADY LAGEL TO THE SACK OF THE BOARD WITH FOLLOWING 2 3 2350 232 EET s CMOS gos ste VERSION 3510824 BULT 08 11 2008 153537 A PERIPHERAL PCL USB STD AND PC 104 BUSSES 8 PERIPHERALS PORTA ADDR Ox033 PORT ADDR PORT ADDR OSEB IRQ 5 PORT D ADDR DEB IRG 9 PARALLEL PORTS ENABLED ADDR 04278 IRO NONE MODE COMPATIBLE Ass RO 12 TO MOUSE DISABLED INTERNAL CONTROLLER MODE SECONDARY CONTROLER OUTPUT DISPLAY PANEL AND CRT FLAT PANEL CONFIGURATION RESOLUTION 640x480 USB AND STD BUSSES el INTERRUPT STEERING Pol tag Fo 12 NONE PCI NIC NONE ITD NONE E Pe 104 Bus PC 102 INTERRUPT STEERING DISABLED ENABLED Mos O1SABLED IRO DISABLED RO ENABLED WS DISABLED ROTO ENABLED Raz DISABLED Trove DISASLED TROIS ENABLED 28 4 Li uE wages EMERSON 23504 prno Management 8 Eel O gE jer ee CE 21743 mage een E RR CE 21743 COC DE 9 20 10 E Pu ier eras Pr rama Pri NOTES A N AN DEGREASE BARE METAL OF COVER 108 PARTICULARLY GLASS SEAT SURFACE AND GROOVES BOND THE ENDS OF A 22 04 INCH LENGTH OF O RING STOCK ITEM 113 TO EACH OTHER U
106. MPLE RS 485 CONNECTION FROM PC TO GC This section demonstrates an example RS 485 connection from a PC to GC that is accomplished through use of an asynchronous line driver interface device The line driver device serves as an interface between the RS 232 output of the PC and the RS 485 protocol needed for long distance serial input to the GC Specifics of the line driver are as follows Black Box brand model LD485A MP RS 232 RS 485 Multipoint Line Driver RS 232 input to connect to the PC and RS 422 or RS 485 output to connect to the GC RS 485 line terminations are illustrated in Figures A 10 next page and jumper and switch settings to configure the line driver device are listed in Table A 3 NOTE For this example a straight through RS 232 serial cable is used to connect between the PC and the line driver See Section 3 4 4 for additional details about serial communications setups at the GC Controller EXAMPLE AS 485 CONNECTION FROM PC TO GC 2010 Model 00 Gas Chromatograr Serial Line Driver Black Box LDASSA MP Supplemental Wiring Guide Serial Communications A 13 ph GC Controller Terminal Board for field wiring GND TXA TXB RXA OP J5 J6 10 J11 22 22 24 I owe sne 7 N C J5 Comi 6 N C J6 Com2 u 5 en J10 Com3 ane C J11 Com4 gt P22 Com5 3 RxIx 23 P24 Com7 1 Figure
107. NGLE PROJECTION F 12 2 04 DLT 5000336 EM DLT cenene TOERUKES E 6 8 04 DIT EcO XX 203411 EM DLT NE unt s D 1 6 04 HM ECO XX 166242 EM HS amp mm C 10 31 02 RD EC0 XX 158738 EM DLT EMERSON ASSEMBLY 23500 CONTROLEER VIEW B B N A B 10 11 02 RD ECO XX 157611 EM DIT Process Management A 03 26 02 RD ERO YY 10078 EM DLT DRN RD DATE 1 3 02 DAG NO REY N A REV DATE DRN DESCRIPTION APPD DE 20775 PROJ FILE NO NONE FILENAME DE20775F2 DWG DATE 12 01 04 TIME 3 21 ODT 3 26 02 Ents FF see ORDER 72 OF 6 9 ASSEMBLY NOTES D 2 3 INSTALL SYSTEM INTERFACE BOARD TEM 303 ON TOP OF CARDCAGE ASSEMBLY VERIFY THAT Si S SET FOR THE CORRECT SYSTEM REQUIREMENT TERMINATE REMANING RED YELLOW BLUE AND BLACK WIRES FROM CARDCAGE POWER SUPPLY CABLE TO 47 ON SISTEM INTERFACE BOARD PER WIRELIST WL 18009 INSTALL BOARDS AND CABLES INTO CARDCAGE ASSEMBLY PER REQUIREMENTS SEE SHEET 6 CLOSE BOARD RETANNG SLIDE CARDCAGE ASSEMBLY ONTO RETAINING BRACKET IN CASE AND SECURE WIM THE FOUR CAPIVE SCREWS PLUG FIELD TERMNATON POWER SUPPLY CABLE INTO 3 PIN POWER HEADER TBI ON CARDCAGE POWER SUPPLY LOCATE BOTTOM OF BOARD WITH CUIDE PINS THROUGH GUIDE HOLES THEN GENTLY PRESS TOP OF BOARD TD MATE BOARD EDQE CONNECTORS TOGETHER SECURE BOARD TO CARDCADE AS
108. NONE FILENAME DE20779B1 DWG DATE 05 07 04 TIME 1 46 P M LATEST REVISION UNLESS OTHERWISE NOTED ALL DIMENSIONS IN INCHES 015 NOTES rN HOLES FOR MOUNTING BACK OF ENCLOSURE TO MOUNTING PLATE FOR OPTIONAL MOUNTING HOLES ARE PROVIDED FOR MOUNTING BOTTOM OF ENCLOSURE TO MOUNTING PLATE ZB FOUR 4 SOCKET HEAD M10 1 5 x 15MM BOLTS PROVIDED WITH UNIT FOR MOUNTING THE UNIT OUTLINE AND DIMENSIONAL EXPLOSION PROOF ENCLOSURE EMERSON 2350A CONTROLLER Process Management DLT wr 2 19 02 Ets see ORDER 1 OF 1 WARRANTY CLAIM PROCEDURES To make a warranty claim you the Purchaser must 1 Provide Daniel Measurement and Control Inc or Rosemount Analytical Ine with proof of the Date of Purchase and proof of the Date of Shipment of the product in question 2 Return the product to Daniel Measurement Services DMS within 12 months of the date of original shipment of the product or within 18 months of the date of original shipment of the product to destinations outside of the United States The Purchaser must prepay any shipping charges In addition the Purchaser is responsible for insuring any product shipped for return and as
109. NTROLLER conn ew eur s Pi coon UEUk 2 001 concn Enc Figure 5 8 External Loopback Circuit for Testing Digital Input Output Operation DISCRETE DIGITAL INPUTS AND OUTPUTS 2010 Maintenance 5 45 Model 500 Gas Chromatograph 5 10 FUSE PROTECTION power fuse protection for the GC Controller is located on the Terminal Board for Field Wiring AC power surge protection is also provided by two Metal Oxide Varistors MOVE SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Failure to observe all safety precautions could result in serious injury or death To locate and replace the Controller s fuse note the following th Figure 5 9 AC Fuse Holder on the GC Controller Terminal Board Lower Left Corner Fuse Location Inside small black holder by lower left corner of the GC Controller TB by label FI see Figure 5 9 Spare fuses are in a small box attached to the GC Controller uiv 2010 FUSE PROTECTION 546 Maintenance Model 500 Gas Chromatograph Fuse Size and Capacity 5 x volts AC slo blo 20 millimeters mm 2 amperes Fuse Replacement Pull fuse holder by its handle away from board then open To locate and replace the DC power supply cable fuse note the following Fuse Location mounted in line with the 5 VDC power supply cable PIN 2 3 2350 005 to System In
110. OMATOGRAM menu allows the operator to view a live chromatogram while the GC System is conducting analysis runs Chromatogram 1 hive GC Control Menu The GC CONTROL menu enables the operator to stop calibrate or place on automatic control a sample stream from the Analyzer This may occur number of times while modifying inputs in the OPERATOR INPUTS menu Entering HALT will allow the Analyzer to finish the presently running operating sequence Entering STOP NOW orders the Analyzer to stop immediately and may require that some parameters be reentered In most eases the GC Control menu will operate in the AUTO mode Control 1 Auto 2 Single Stream 3 Calibration Halt Alarms Menu JULY 2010 Model 500 Gas Chromatograph 437 438 Operation from Local Keypad and Display 4 17 GC Control 5 Stop Now Data Records Menu The DATA RECORDS submenu will be particularly helpful to maintenance personnel when a problem occurs in one or more of the streams view of the Raw Data or Analysis Reports can help in isolating or indicating areas that may need maintenance attention Saved periodic historical reports will allow maintenance personnel to review the operation of the GC System and often head off incipient problems Data Records 1 Raw Data 2 Raw Data 3 Raw Data a Analysis 5 Cal Results Stream Data Config Rpt Maint Log Menu
111. ON OF PROBLEM WHAT WAS HAPPENING AT TIME OF FAILURE ADDITIONAL COMMENTS REPORT PREPARED BY IF YOU REQUIRE TECHNICAL ASSISTANCE PLEASE FAX OR WRITE THE CUSTOMER SERVICE DEPARTMENT AT DANIEL MEASUREMENT SERVICES DIVISION OF EMERSON PROCESS MANAGEMENT PHONE 713 827 6350 ATTN CUSTOMER SERVICE FAX 713 827 6312 11100 BRITTMOORE PARK DRIVE HOUSTON TEXAS 77041 FOR FASTEST SERVICE CONTACT DANIEL MEASUREMENT SERVICES VIA OUR WEBSITE www emersonprocess com daniel This page is intentionally left blank Daniel Measurement and Control Inc Daniel Measurement Services Inc and Rosemount Analytical Inc Divisions of Emerson Process Management reserves the right to make changes to any of its products or services at any time without prior notification in order to improve that product or service and to supply the best product or service possible www emersonprocess com EMERSON Process Management
112. ONVERSION PROCESS G4 gt 2350 to 2350A CPU Retrofit Instructions Model 500 Gas Chromatagraph 1LRemove any other optional boards such as memory expansion boards and associated cables These parts are not used on the 2350A GC Controller 12 Leave the Analog Board assembly drawing P N BE 18044 with attached cable in the card cage This board is used on the 2350A basic configuration 18 Change the fuse in the inline fuse holder from 1 amp to the 2 5 amp Slo Blo fuse provided The fuse is located in the cable PIN 2 3 23 069 between the power supply and the System Interface Board 14 Ensure that DIP Switches 6 7 and 8 of S1 are all in the position If the 2350A is powered up with in the ON position it will delete the current application commonly called a Cold Start 15 To inspect or change the GC Controller s COM ID setup at the GC Controller site locate the DIP switch as described in the following stops 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 or death sult in serious injury CONVERSION PROCESS uiv 2010 2350 to 2350A CPU Retrofit Instructions 6 5 3 Model 500 Gas Chromatograph 16 For the explosion proof Controller
113. OTE EXISTING WIRING CONNECTIONS TO 2251 F 4 gt Upgrading from 2251 to 2350A GC Controller Model 500 Gas Chromatagraph Model 22508 COMM PORT n suse RS232 serial port for serial printer connection L H TEM view serial cable Connection E Terminais Terminais Tera printer MEINE Figure F 2 Replacement Serial Printer Wiring Help Locate the cable that runs from the 2251 Controller to the serial printer if a serial printer is connected to the Controller At the cable s termination at the 2251 make note of each individual wir connection and color Record the colors of each of the serial printer wires by filling out the color box in the wiring guide for the serial printer connection see Figure 2 Again this step is very important Complete the color box accurately but do not remove any wires at this time 3 Locate the cable that runs from the 2251 Controller to the strip chart recorder if a chart recorder is connected to the Controller At the cable s termination at the 2251 make note of each individual wire s connection and color Record the colors of each of the serial printer wires by filling out the color box in the wiring guide see Figure 2 Again this step is very NOTE EXISTING WIRING CONNECTIONS TO 2251 uiv 2010 Upgrading from 2251 to 2350A GC Controller F 5 Model 500 Gas Chromatogr
114. OUS PERSONAL INJURY OR DEATH POSSIBLE not operate a PC or printer in a hazardous environment Failure to observe all or death sty precautions cou utin s injury The 19 inch rack mounted 12 inch rack retrofit kit and the explosion proof NEMA 4X Groups B C and D Controllers all operate identically uiv 2010 CONTROLLER 2 42 Equipment description Model 500 Gas Chromatagraph 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 C and D Connections to the enclosure are through one 2 inch 50mm hole reduced to 3 4 inch with bushing and two Lineh 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 STATUS ALARM LEDs Roma mmm ABBE BEB Figure 2 8 GC Controller Bxplosion Proof Version Controller Hardware Configurations uiv 2010 Equipment description 2 13 Model 500 Gas Chromatograph STATUS ALARM LEDe om gt 9 lt EB 5 c ds Figure 2 4 GC Controller 19
115. PU Retrofit Instructions lt G 7 Model 500 Gas Chromatograph Table G 1 Modbus Slave Address COMID Dip Switch Settings Switch Positions z a n 1 ON or or or orr or or Jorr 1 ON ON or jor orr 1 or Jorr om orr 5 or or or ON or 7 ON ON ON or s or or or os OFF RAM CLEAR Dip Switch Setting Switch Positions Clears RAM when unit powered down Keeps RAM when unit powered down G 3 BASIC 2350A CONFIGURATION At this point install if any all mounting hardware and optional PC 104 boards onto the 2350A CPU Board 1 Install the 2 assembly JA CPU P N 3 23504 190 into slot 3 of the card cage 2 Install cables on the CPU Board in the following sequence a Digital 1 0 cable PIN 3 2 Interface Board J2 0 Digital 1 0 cable PIN 3 2 Interface Board 23 50 081 from CPU J7 to the System 50 080 from CPU J4 to the System uiv 2010 BASIC 2350A CONFIGURATION 6 8 gt 2350 to 2350A CPU Retrofit Instructions Model 500 Gas Chromatagraph c 1 COME and the printer cable PIN 3 2350 083 from CPU J1 to the System Interface Board J4 J9 and J11 d COMS and can be configured two different ways To configure a system WITHOUT a keyboard and display connect cable PIN 3 2350 084 from CPU J6 to the System Interface Board 38 a
116. Part 2 Industrial Environment and EN50081 2 Electromagnetic Compatibility Generic Emission Standard Part 2 Industrial Environment The three versions of the GC Controller the explosion proof the 19 inch rack mount and the retrofit are all qualified for the European Compliance Engineered CE mark In fact the GC Controller far exceeds many of the minimum requirements for that mark 2 Guide to Transient Protection Modules Model 500 Gas Chromatograph C 2 PART APPLICATIONS NUMBERS AND DESCRIPTIONS are installed on the rear side of the GC Controller s Terminal Board for Field Wiring TB The TB is available from Emerson Process Management in various premanufactured versions with preassigned TPM installations designed to handle specific combinations of applications A table that lists the premanufactured TB versions or con figurations is provided in drawing CE 18118 Sheet 3 see Addendum 2 GC Controller Drawings this manual There may be times when it is more appropriate to change inspect diagnose or service the individual TPMs rather than the entire Terminal Board TB Consequently this section of the Appendix provides a guide to the individual TPMs installed on the TB their uses and their part numbers see Table C 1 following page Further Explanation Individually the TPMs can be divided into two main categories differential and single ended modules
117. ROTECTION MODULES This Appendix provides a field service guide to the transient protection modules TPMs installed on the Terminal Board for Field Wiring TB of the Gas Chromatograph Controller This Appendix is organized as follows Purpose of the Transient Protection Modules Part Applications Numbers and Descriptions Troubleshooting Transient Protection Modules PURPOSE OF THE TRANSIENT PROTECTION MODULES The field wiring transient protection modules TPMs used on the GC Controller prevent the conduction of potentially damaging high voltage short duration transient signals into the GC Controller s internal electronics The transient signals filtered out by the TPMs originate from sources that affect the input output connections of the GC Controller This includes connections to stream switching systems analog and digital input output devices and serial communications devices The transient signals may be caused by the devices themselves or by environmental conditions that induce signals through the input output cabling Additionally the GC Controller was designed to comply with European requirements Inspections required for compliance include tests for electrostatic discharge radiated immunity electrical fast surge immunity conducted RF and magnetic field immunity The tests conform to the electromagnetic compatibility generic requirements of EN50082 2 Electromagnetic Compatibility Immunity Standard
118. RRENT ANALYSIS AND POWER UPGRADING FROM DOWN 2251 TO 2350A GC CONTROLLER 2 EXISTING WIRING CONNECTIONS TO 2251 I F2 F3 CABLES REPLACE CONTROLLER AND RECONNECT mM APPENDIX G 235070 G 1 2350A CPU ASSEMBLY INTRODUCTION G 1 2350A CPU RETROFIT INSTRUCTIONS 6 2 CONVERSION PROCESS G 3 2350A CONFIGURATION GA 2380A 5 ua GD G 4 1 The COM4A Board ca G8 TO ADD A MODEM 2 G S ADD AN ETHERNET CARD APPENDIX H 2350A H 1 INTRODUCTION HOD LX 800 CPU RETROFIT INSTRUCTIONS H 2 REMOVING THE OLD CPU CARD H3 INSTALLING THE NEW CPU BOARD H 8 H4 INSTALLING A KEYBOARD AND DISPLAY WITH COMMA BOARD MP 2010 Appendix D Internal Modem for GC Controller 8 TABLE OF CONTENTS Model 500 APPENDIX F SHIPPING AND LONG TERM STORAGE RECOMMENDATIONS ADDENDUM 1 ADDENDUM 2 HS 2 INSTALLING KEYBOARD AND DISPLAY WITHOUT COM4A H8 RETROFITTING THE ANALOG BOARD Identifying your Analog Board Installing New Analog Board REASSEMBLING THE 2350 Appendix F Shipping and long term storage recommendations 2010 DESCRIPTION 1 1 AAA 112 1 1 3 114 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 se
119. SEMBLY WIH SIK SCREWS CONNECT GROUND STRAPS To Wi AND NA STANBOFFS ON FELD TERMINATION BD ae 96909 w INSIDE VIEW WITHOUT CONNECTOR PLUGS Su T CCE Ss TRT ETE RSL a LETT LLL EEE E EST C D 1 6 4 ECO IX 1662477 as EES EMERSON SDS a wa apera m eooc win PEERS dau TSE aor Ek na m wm museums EP FTE IF 20775 T TRE o WOME DEROTEFBDWG DATE 12 01 04 THE 328 pen se aimee Ems PZ sn oR PS oF 2 MIN NN Wi A ws i 77 M10 1 5 66 X 50 MM 302 STAINLESS STEEL NOTES ATTACH HINGE HALVES ITEM 402 TO COVER AND CASE WITH SCREWS DRAWING AE 12672 TO TOP OF UNIT SI METRC TWORK IT SHALL NOT BE REPRODUCED AND SHALL BE RETURNED TO US THIRD ANGLE PROJECTION F 12 2 04 DLT ECO XX 5000336 EM DLT am ae E 6 8 04 DLT ECO XX 203411 EM DLT n PER e D 1 6 04 EC0 XX 166242 tu HS LATEST REVISION m C 10 31 02 RD EC0 XX 158738 EM DLT N A B 10 11 02 RD ECO0 XX 157611 EM DLT Process Management si A 03 26 02 RD ERO YY 10078 EM DLT N A REV DATE DRN DESCRIPTION DWG NO DE 20775 ITEM 408 M
120. SING ANAEROBIC ADHESIVE P N 9 9960 027 OR EQUIVALENT PUT THIS SEAL IN WINDOW GROOVE IN COVER JN GLASS ITEM 107 PLACE GLASS IN COVER FOR UNITS WITHOUT A DISPLAY AND KEYPAD INTALL BLACK FIBERGLASS BOARD ITEM 370 1 IN BACK OF GLASS RIGHT SIDE BACK VIEW SO THAT IT DOES NOT I A COVER WHERE LED INDICATORS ARE LOCATED CLAMP FIRMLY USING RETAINERS ITEM 106 AND FASTENERS ITEMS 117 amp 121 UNIFORMLY TIGHTEN 25 35 INCH POUNDS SPACE BETWEEN GLASS AND ENCLOSURE NOT TO EXCEED 002 INCH FOR DETAIL OF GLASS SEE DRAWING BE 12652 1 MOUNT KEYPAD ASSEMBLY ITEM 122 TO FRONT OF COVER USING TAMPER PROOF SCREWS ITEM 115 AND SE L SCREW ITEM 120 INSTALL LOGO PLATE ITEM 104 USING DRIVE SCREWS ITEM 116 gt N INSTALL WARNING LABEL ITEM 109 INSTALL LED LEGEND LABEL ITEM 105 CLEAN SURFACE WITH 3M ADHESIVE CLEANER P N 9 9960 179 INSTALL SPACERS ITEM 111 MOUNT KEYBOARD ITEM 101 ON SPACERS INSTALL SPACERS ITEM 110 IN COVER INSTALL DISPLAY ASSEMBLY ITEM 102 ON SPACERS UNACK ALARM gt PP BOND THE ENDS OF A 40 60 032 LENGTH OF O RING STOCK ITEM 114 WORKING TO EACH OTHER USING ANAEROBIC ADHESIVE P N 9 9960 027 OR ACTIVE ALARM EQUIVALENT A MAXIMUM OF 015 OFFSET IS PERMITTED PLACE A VERY SMALL AMOUNT 1 WATER DROP SIZE OF RTV SILICONE P N 9 9960 065 IN THE SEAL GROOVE AT 8 EVENLY SPACEO LOCATIONS PRESS SEAL IN GROOVE AND ALLOW TO SET INSTALL RIBBON C
121. See Figure 4 2 and Table 4 2 Table A a GGBaE Figure 4 2 Local Site GC Controller Keypad 433 Local Keypad Key Strokes and Their Functions Numerals Period and Minus Sign Far entering numeric data or function codes nter ENTER Tog on to the menu and or move to the next field saving the current value Inputs into memory any valid data shown on the alphanumeric display 1f no data has been entered ENTER causes skip to the next field Escape ESC Exits the current menu and saves the current values A pop up sereen will ask if changes should be saved YES or NO Up Arrow Causes a move up one field and saves the current value Down Arrow Causes move down field and saves the current value left Arrow Causes move left one apace and saves the current value Right Arrow Causes a move right one space and saves the current value Next NEXT Goes forward to next set of data eg if stream 1 value set ie dis played goto data in stream 2 Also exits the current data set and saves the values Increment NCR Adds an item to timed event TEV or component data CDT tables used to page up in a list that covers more than one display AUT and INCE keys Decrement DECR Deletes an item from the TEN or CDT tables or used to page down in list that covers more than
122. The differential modules are used with two wire analog signals so that both wires are protected Single ended modules are usually used to clamp digital signals Finally in those eases where high current or high voltage are needed for discrete outputs a TPM is substituted that has no protection devices Table C 1 Transient Protection Modules Installed on the Terminal Board for Field Wiring APPLICATION PART NO PART DESCRIPTION SOCKETS channel COM 2350 0 Quad Bidir Sngl Tost M6 COMI COMB COM COMO COM jaa 33350027 Quad Bidir Sngl Tas M11 COMB COM3 COM 2350 0 Quad Bidir Sngl nst M6 COMI COMB COM MT COMO PART APPLICATIONS NUMBERS AND DESCRIPTIONS JULY 2010 Guide to Transient Protection Modules lt C 3 Model 500 Gas Chromatograph APPLICATION PART NO PART DESCRIPTION wes SOCKETS channel 32350002 Quad Sngl Tast MS Pact codes M15 FC Strobe A Zero Alarm STREAM 32350002 Quad Sngl Tast M16 Gol 1 0 SWITCH M10 Sol 5 8 DIGITALUO 32350 002 Quad Sngl Tast MS Din D aow MI Din 25 CURRENT M5 Dout 5 NOTES 16 pin DIGITALO 3 2350 003 Quad Diff Tast Dout 1 4 ANALOGIO 32350 003 Quad Dif Tust MI Ain 1 0 MIS Ain 59 M12 Aout 1 2 M3 Aout 3 6 M2 Aout 7 10 NOTES 20 pin
123. 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 writing signed by an authorized representative of Seller Except as othenwi expressly provided in the Agreement THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND EXPRESSED OF IMPLIED AS TO MERCHANTABILITY FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES It 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
124. YZER OVEN SAMPLE VENT lt e x FLOW PANEL SOLENOID u Rays wate N PE ar STREAM 2 Loop o 0 9 STREAM IN pL STREAM BYPASS t Ea ea sa s ses PLATE ee P RO c4 ES eee END HERE e AEBS EMERSON ai dwn m khien is RES N E FENCE GR m e iom o T roe TT T TUTEIX ITI SE cames SAMPLE VENT 449 ANALYZER OVEN FLOW PANEL NOTES a CURT comecpons 1 8 SOLENOID WIRING BANE csp VS RD ee m STREAM 2 IS Temas num nr vs E else LT I TEIGXTI UTR amp EMERSON 007 wa pump ne i me ee me Red x mi srl pe ana ge oe cc 1e2 t ee 6 ex NOTES CAL STO IN S STREAM 3 STREAM 1 gt BYPASS 1 a STREAM 2 BYPASS 2 4 Yampassssw tin des vent et ce x nor eme V
125. able 2 1 Contents of Example Calibration Gas Gas Mole Percent Nitrogen 25 Carbon dioxide Methane Balance Ethane Propane 10 Isobutane N butane 03 Neopentane o1 opentane o1 N pentane o1 N hexane 0 03 The sampling system should be carefully planned for the best chromato graphic analyses Calibration Gas JULY 2010 Equipment description lt 2 5 Model 500 Gas Chromatograph 22 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 Pneumatical carrier gases actuated valves that control the flow of the sample and 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 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 uiv 2010 ANALYZER 2 6 5 Equipment description Model 500 Gas Chromatograph Upper XJT Box Analyzer Valves Columns Detectors Heater
126. able cell Use the provided pull down menu and click on the desired variable to select it fsa cou sor cae SCF Ee Ss Lay EZ kas isa vau Goes BTU D stra vane Bross BT So atra aue Biss BTU act Wald vaus Na ETU DY Hated Vas sa stra val ETU A vous inu muy entra vate up IE Sa Head ae Sie MEAL EET feang vane Hecate Se gbg Changing a Variable 2010 Maintenance 5 35 Model 500 Gas Chromatograph 5 8 3 Changing the Bargraph Use this function to designate which AEM output analog signals be used to drive the bargraph device inputs Each of the 16 available AEM output signals can be assigned to represent various GC analysis data variables 1 To edit the variables and corresponding settings displayed by the bargraph click on the BARGRAPGH button or press the F5 key a The Bargraph dialog box appears b To edit the settings displayed double click on the appropriate cell or click and use the provided pull down menus See Section 5 8 1 Analog Output Dialog Description on page 32 for more details Multiple streams can be entered by commas 2 3 Bargraph results will be produced for each uiv 2010 Changing the Bargraph 5 36 Maintenance Model 500 Gas Chromatagraph 2 change a variable assignment click on the appropriate Variable cell Use the provided pull down menu and clic
127. access to serial port 4 on the field termination board 3 Plug the 10 pin connector labeled INTF J8 into the header labeled J8 the system interface board for access to serial port 3 on the field termination board 4 Plug the 10 pin connector labeled INTE J12 from the COM4A board s ribbon cable PIN 3 2350 151 Rev A to the header labeled J12 on the system interface board This dedicates serial port 8 to the keyboard and display interface 5 Start MON2000 and do the following a Select Serial Ports from the Application menu b Set the Usage for serial port 8 to Front Panel Installing a Keyboard and Display with COMAA Board 2010 Model 500 Gas Chromatograph H5 6117 CPU to LX 800 CPU Upgrade Instructions lt H 9 c Click OK The mode RS 232 RS 422 or RS 485 for the first four serial ports COMI COMA can also be set through MON2000 the remaining ports COMS COME must be set manually See COM4A RS 232 RS 422 RS 485 Configuration on page 3 51 for more information about configuring the COMS COMB ports The CPU board installation is complete If you plan to install a new analog board go to Retrofitting the Analog Board on page H 11 otherwise go to Reassembling the 2350A on page H 13 INSTALLING A KEYBOARD AND DISPLAY WITHOUT COMA BOARD To connect a keyboard and display to a CPU assembly without board do the following 1 Conn
128. ach card in an anti static protection bag 4 Unscrew the two nylon spacers to which the faceplate was mounted Disconnect the three power leads from the terminal strip TBI in the lower right corner of the Decoder board 6 Disconnect the brown connectors at the top Grasp each connector by its top and bottom side and depress to release the hold down catch Only a small pressure is required but the connector must be fully engaged for the latch to release Pull the connector with a left right up down motion until it disengages A screwdriver will help in depressing the top catch 7 Release the four captive screws holding the board in the rear of the electronics housing 8 Pull the card forward to release it from the two studs near the center top and bottom of the board 9 Remove the board maintaining the wire bundles in the center top and bottom of the electronics housing opening Pull the lower end of the board out through the opening while pushing the top end of the board into the top rear of the housing The card guides are mounted so that they can flex sideways during board removal uiv 2010 Decoder s12 Model 500 Gas Chromatagraph Instructions for Reinstalling the Decoder Board SERIOUS PERSONAL INJURY OR DEATH POSSIBLE d when the unit is o the explosion taken to ensure that The explosion proof housing should not be op exposed to an explosive environment If acces proof housing i
129. alue in engineering units read by the receiving device e g a voltmeter 11 Set Fixed Value equal to the Full Scale value see Step 2 12 Click OK to accept your changes and exit from the Analog Outputs dialog box 13 Return to the Analog Outputs dialog box Wait until the Current Value of the analog output is equal to the Full Seale value see Step 2 14 Record the value in engineering units read by the receiving device e g a voltmeter 15 Set Zero Adjustment to the value calculated from the following formula Zaro Zaro Scale arcana x SesleRange Onan where OutputRange The Ideal Full Scale Analog Output Value minus the Ideal Zero Scale Analog Output Value ZeroScaleError The Ideal Zero Seale Analog Output Value minus the actual measuered Zero Scale value from the analog output ScaleRange The Full Scale value minus the Zero Seale value 16 Set Full Adjustment to the value calculated from the following formula where OutputRange The Ideal Full Scale Analog Output Value minus the Ideal Zero Scale Analog Output Value JULY 2010 Maintenance 5 39 Model 500 Gas Chromatograph FullScaleError The Ideal Full Seale Analog Output Value minus the actual Full Seale value measured at the analog output SealeRange The Full Scale value minus the Zero Seale value 17 Set the Fixed Var parameter to 18 Click OK to complete the calibration and return to the main w
130. aph important Complete the color box accurately but do not remove any wires at this time Figure F 3 Replacement Chart Recorder Wiring Help REMOVE CABLES REPLACE CONTROLLER AND RECONNECT To finish the GC Controller replacement follow these steps 1 Turn OFF the 20 volt power supply at the Model 500 Analyzer a Remove the cover of the lower explosion proof electronics housing of the Model 500 Analyzer this housing contains the 20 volt power supply switch and the five stream switches for the Analyzer uiv 2010 REMOVE CABLES REPLACE CONTROLLER AND RECONNECT 6 gt Upgrading from 2251 to 2350A GC Controller Model 500 Gas Chromatagraph b Turn OFF the 20 volt power switch located at the top left At this point all lights in the lower explosion proof housing of the Model 500 Analyzer should be OFF SERIOUS PERSONAL INJURY OR DEATH POSSIBLE The above step is avoid personal injury Failure to observe al se or dest precaution that must be followed to sty precautions could result in serious injury Remove all cables from the 2251 GC Controller terminal 3 Remove the 2251 GC Controller and install the replacement 2350A GC Controller SERIOUS PERSONAL INJURY OR DEATH POSSIBLE NOT connect the 2350A GC Control time to AC power at this Failure to observe all safety precautions could or death
131. ard determine whether your Model 2350 controller currently has a 12 bit 16 bit analog board compare ita appearance to the following pictures 16 b analog board Ifa visual inspection is difficult to perform you can use MON2000 to determine which analog board is currently installed To do so do the following 1 Start MON2000 and connect to the appropriate GC uy 2010 Retrofitting the Analog Board i Instructions Model 500 Gas Chromatograph 2 Select Analog Inputs from the Application menu 3 Compare the values listed on the Analog Inputs window to the typical values listed in Table H 1 Table H 1 The typical ranges for Model 2250 and Model 3350A Controllers GC GRI PAZQLbRAD PAZ 16 bit AD ECTS EDITI 2 udo DPI Sto dedos 32767 to 32767 a ostii Ot 32767 to 32767 In this example the PAZ values are all found within the ranges expected with a 16 bit analog board As sueh this controller ean be upgraded without upgrading the analog board Identifying your Analog Board 2010 H 6 2 8117 CPU to LX 800 CPU Upgrade Instructions H 13 For more information or questions about purchasing the appropriate 16 bit analog board contact the Customer Service at GC CSC emerson com or 713 827 6380 Installing a New Analog Board install the analog board do the following 1 Place the analog board P N 3 2350 034 or 3 2350 041 in
132. ard s with stream switches Manually turn the switch for stream 1 ON and turn all other streams OFF Open the purge valve associated with stream 2 and regulate the flow through the solenoid purge flow indicator to approximately 200 cubic centimeters per minute cem Refer to the sample system drawing for the location of purge valves 6 Open the purge valve associated with stream 3 and regulate the flow through the solenoid purge flow indicator to add approximately 200 cem to current flow Flow indicator should now read 400 cem 7 Continue to open solenoid purge valves adding 200 cem flow for each additional stream as measured at the solenoid purge flow indicator 8 When flows for all streams except stream 1 are set manually turn stream 1 OFF at the Analyzer Valve Driver board a Now manually turn stream 2 ON at the Analyzer Valve Driver board Next open the solenoid purge valve associated with stream 1 to add 200 cem to the current flow as measured at the solenoid purge flow indicator 9 When all flows have been set return all stream switches to AUTO positions at the Analyzer Valve Driver board 10 After you have set all stream switches to AUTO positions close the XJT electronics box that houses the Analyzer Valve Driver board and commence normal analysis JULY 2010 APPENDIX F UPGRADING FROM 2251 TO 2350A GC CONTROLLER FA This appendix provides the steps needed to replace a 225
133. as Chromatograph This page is intentionally left blank TROUBLESHOOTING TRANSIENT PROTECTION MODULES JULY 2010 APPENDIX D INTERNAL MODEM FOR GC CONTROLLER This Appendix provides additional information for installing the internal modem for the GC Controller See drawing BE 20767 in Addendum 2 of this manual To install the Internal Modem for the GC Controller follow these 1 Halt any ongoing analysis runs 2 Disconnect AC power from the GC Controller SERIOUS PERSONAL INJURY OR DEATH POSSIBLE fore removing the cover from the Model 500 make certain the power supply switch is OFF and the AC power cord is disconnected Failure to observe all safety precautions could result in serious injury or death The folowing stops for accessing the various Controller electronics steps 3 through 6 proof Controller 3 Remove the cover from the GC Controller housing to expose the GC Controller s Terminal Board for Field Wiring 4 Loosen the six screws that secure the GC Controller s Terminal Board for Field Wiring Then unplug the Terminal Board from its connections at the back top of the board 02 Internal Modem for GC Controller Model 500 Gas Chromatagraph 5 Lower the Terminal Board down and out of the way held in place by its ground straps at the bottom of the board This exposes the Card Cage Assembly 6 Loosen the four serews that secure the Card Cage Assembly to the chassis The
134. as Lines uiv 2010 Installation and Setup 3 81 Model 500 Gas Chromatograph 3 Ensure that all of the Analyzer Valve Switches upper XJT box are set to the AUTO position Upper XJT Box Analyzer Valves E asam Columns Detectors KA Heater and Up KLA Preamplifier uU Aand temps controler mem Analyzer valve switches Flow Panel Lower XIT Box Lower XJT Box sos Mounting Sampie system valve te aver board ANALYZER Figure 3 28 Location of Analyzer XJT Boxes suty 2010 Purging Carrier Gas Lines 3 82 Installation and Setup Model 500 Gas Chromatograph 8 nupcr Cile anus Cs consst asr Figure 2 29 Analyzer Valve Switches Upper XJT 4 Ensure that all of the Analyzer Valve Switches upper XJT box are set to the AUTO position 5 Ensure that the carrier gas bottle valve is open 6 Set the carrier gas line pressure at 115 psig Use the dual stage regulator at the carrier gas bottle to adjust pressure Pressure Adjust valve on the Flow Panel of to adjust carrier gas ine pressure That val factory set and should not be adjusted Purging Carrier Gas Lines uiv 2010 Installation and Setup 3 83 Model 500 Gas Chromatograph 7 Allow the Analyzer system temperature to stabilize and the carrier gas lines to become fully purged with carrier gas A period of 4 to 8 hours or overnight is recommended during which all of th
135. assis ground to an external copper ground rod at remote locations See Section 3 1 4 Electrical and Signal Ground on page regarding electrical and signal ground 3 5 ANALYZER LEAK CHECKS AND PURGING FOR FIRST CALIBRATION 3 5 1 Analyzer Leak Checks Install Analyzer Wiring Install Analyzer Sample amp Gas Lines Install GC Controller Wiring Perform Leak Checks perform Analyzer leak checks follow these steps 1 Plug the Measure Vent labeled MV vent line if it is open The SV or Sample Vent line should be left open or unplugged 2 Slowly pressurize each line in turn then block in the line making sure the pressure holds ANALYZER LEAK CHECKS AND PURGING FOR FIRST CALIBRATION uiv 2010 Model 500 Gas Chromatograph Installation and Setup 3 79 For example the carrier gas line should be slowly brought up to 110 psig 42 percent with the dual stage regulator at the carrier gas cylinder After 2 minutes shut the carrier gas bottle valve and observe the high side regulator gauge on the carrier gas bottle a The gauge should not bleed down more than 115 psig in 10 minutes b If helium is lost at a faster rate leaks are usually found between the carrier gas bottle and the analyzer Check and tighten all connections as well as the dual stage regulator When the leak check is complete reopen the helium bottle valve Remove the plug from the MV line R
136. atically handled This is done by testing each termination point to see if the region immediately following it satisfies the criteria of a baseline 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 2010 Peak Detection 112 154 Description Model 500 Gas Chromatograph 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 mi
137. ation 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 uiv 2010 Power Source Wiring 3 6 5 Installation and Setup Model 500 Gas Chromatograph Controller and any optionally installed sample oven or stream switching devices are all protected by one circuit breaker 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 Metrie 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 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 Plan Site Location 1 2 Obtain Supplies and Tools 4 Install Analyzer Wiring Follow these general precautions for field wiring digital and analog input output lines 1 Metal conduit must be used for all process signal wiring 2 Metal conduit used for process signal wiring
138. ation 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 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 autom
139. ations can be sot with 0 mA output and full scale calibration can be set with up to 22 5 mA output Refer also to Drawing DE 20782 If there is reason to suspect that the span on any particular channel might be off after a period of time and heavy use then the analog output for that channel should be recalibrated uiv 2010 GC Controller Address Change 5 32 gt gt Maintenance Model 500 Gas Chromatagraph 5 8 1 Analog Output Dialog Description 1 Use the Application gt Analog Outputs menu path to access this function 2 The Analog Outputs dialog box appears sen cap m me edit the settings displayed double click on the appropriate cell or left click the mouse button and use the provided pull down menus When assigning analog output Config feld in the System output assignment that us setting will produce incorrect scaling first check the CGM Analog Output log box see Section 5 1 An analog he same analog output number as the stie CGM trace output possibly with See the following table for details Analog Output Dialog Description JULY 2010 Model 500 Gas Chromatograph Maintenance 5 33 Table 5 5 Description of Analog Output Settings Setting Description Number Number label assigned Number of available analog outputs is dependent upon the GC control ler modal Note Ifthe GC unit includes an Analog Expansion Module AEM PN 1 0500 0
140. ay 4 13 Main Menu 1 Hardware Streams Analog Inputs 3 Analog Outputs Discrete Inputs Discrete Outputs Valves Current GRI Values 2 Operator Entries Components 2 Timed Events 3 AnalysisiCycle Time Calculation Control User Defined 3 Alarms Limit Alarms Discrete Alarms Active Alarms Unackd Alarms 4 Chromatogram 1 Live 5 GC Control 1 Auto 2 Single Stream 3 Calibration i Hale op Now 2010 LOCAL DISPLAY MENUS 4 14 gt gt Operation from Local Keypad and Display Model 500 Gas Chromatograph Data Records Raw Data Raw Data 2 Raw Data 3 Analysis Cal Results Stream Data 7 Config Rpt Maint Log 1 Reports PC Contig Maintenance Log Figure 44 Menu Tree for Local GC Controller Keypad Display Main Menu The Main Menu serves as the entry point into all submenus below it Main Menu 1 Hardware 2 Operator Entries Alarms 4 Chromatogeam 5 GC Control 6 Data Records Config Rpt Maint Log 4 3 2 Hardware Menu The various submenus of the HARDWARE menu allow an operator to define the stream functions analog inputs outputs diserete inputs outputs adjust the scales and range of the inputs outputs within limits Main Menu JULY 2010 Operation from
141. be disconnected for refiling without interrupting GC open 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 uiv 2010 Installation and Setup 3 29 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 e 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 to follow tubing the proper S C 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 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 Sample gas stream inlot s are identified in the applicable Sample Con
142. bly COM4A Serial Board Sheets 1 2 Assembly CPU Board 2350A Assembly CPU Board 2350A 32 BIT Assembly Sheet 5 of 6 Card Cage Detail Dimensional 19 Rack w Display amp Keypad Dimensional Explosion Proof Unit Dimensional 19 Rack w o Display amp Keybd Dimensional Panel Mount Unit 2250 Retrofit Field Wiring Terminal Board 22 gt Addendum 2 Model 500 Gas Chromatagraph aie ate pom Block Diagram of GC Controller Circuit Boards 2010 ed q gt ASSEMBLY NOTES DANIEL TO INSTALL SERIAL NUMBER LABEL AS INDICATED BRADY LABELS SHOULD BE PLACED ON CIRCUIT SIDE OF BOARD CENTERED BETWEEN SOCKETS OF U6 AND U7 SHADED COMPONENTS ARE NOT INSTALLED U6 AND U7 ARE OPTIONAL COMPONENTS DEPENDING ON THE NUMBER OF ANALOG CHANNELS REQUIRED SEE TABLE INSTALL 22 GA BUS WIRE ITEM 3 ACROSS PINS 1 AND 2 OF 015 018 INSTALL U9 IN SOCKET AFTER ASSEMBLY MASK OFF GOLD FINGERS AT LOCATION 1 TWO DRAIN HOLES INSIDE SOCKET FOR U9 ON CIRCUIT SIDE U9 SOCKET P ON COMPONENT S
143. ch channel consists of installing and or removing the appropriate line driver ICs and installing the required jumpers Appropriate jumpering chip installation and the output connector pin out is shown for each of the channels in each mode 2010 CPU and COMBA Se ial Communications Setups 3 52 5 Installation and Setup Model 500 Gas Chromatagraph Channel 1 10 Connector J6 CHANNEL 1 RS 232 MODE V6 MAX208CNG INSTALLED UB REMOVED 2 T77 cut opo Caries Detect 19 8 DSR Rosa 29 97 RIS Boa GTS 07 R GND 8 CHANNEL 1 CHANNEL 1 RS 422 MODE RS A85 MODE ue REMOVED REMOVED Us 75176 INSTALLED U3 REMOVED Ud T8176 INSTALLED UA 75178 INSTALLED E cr eo fees Ne Te es Ne ig 2587 mee 2 9 z Ne TRX 38 88 NE Ne 1009 Ne 49 cho 6 ND 5 0 Figure 3 12 Channel 1 1 0 Connector J6 CPU and COMAA Serial Communications Setups JULY 2010 Installation and Setup 3 53 Model 500 Gas Chromatograph Channel 2 UO Connector J6 CHANNEL 2 5 732 MODE MAX208CNG INSTALLED U10 REMOVED U14 REMOVED CHANNEL Bare RS 485 MODE U13 REMOVED ra REMOVED REMOVED UID 7517 INSTALLED U14 7517 INSTALLED U14 75176 INSTALLED Figure 3 13 Channel 2 1 0 Connector J6 4 Communications Setups 2010 CPU an
144. ching 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 54 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 use either RS 232 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 suty 2010 Equipment description 2 17 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 The optional
145. ctrical Mechanical Safety and Integrity Certifications and Classifications Both the Analyzer and the GC Controller when housed inside explosion proof 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 C and and Canadian Standards Association 8 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 uiv 2010 Equipment description 2 19 Model 500 Gas Chromatograph EEx d IIB T6 Meets CENELEC EN 30 014 and EN 50 018 Electrical Apparatus for Potentially Explosive Atmospheres Parts Land 5 as flameproof for Group II Subdivision B Temperature Class 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 8 A C22 2 No 94 1967 as C S A enclosure 4 and International Electro
146. d Ser 3 64 gt Installation and Setup Model 500 Gas Chromatagraph Channel 3 UO Connector J3 CHANNEL Rs 232 MODE U11 MAX208CNG INSTALLED U9 REMOVED U12 REMOVED CHANNELS 5 488 MODE un REMOVED Ut REMOVED Ug 75176 INSTALLED REMOVED Ut2 lt 75178 INSTALLED U12 75176 INSTALLED H HI Bo 1 Ha 089 Figure 3 14 Channel 3 1 0 Connector J3 CPU and COMAA Serial Communications Setups JULY 2010 Installation and Setup 3 55 Model 500 Gas Chromatograph Channel 4 UO Connector J3 CHANNEL 4 Rs232 MODE US MAXZOBCNG INSTALLED Vi REMOVED UP REMOVED R5 485 MODE us REMOVED Us REMOVED UI 75176 INSTALLED U1 REMOVED U2 78176 INSTALLED U2 75178 INSTALLED TIT ch pes x m Figure 3 15 Channel 4 1 0 Connector J3 uiv 2010 CPU and COMAA Ser 4 Communications Setups 3 56 gt gt Installation and Setup Model 500 Gas Chromatagraph COM4A RS 232 Configuration Ports Maximum number of RS 232 ports available seven see Section 3 4 5 Controller Printer Wiring on page 69 which are routed to DB 9 plug connections female P2 COM1 and P22 COMB P23 COMB P24 COM Phoenix plug connections or bare wire connections G Controller TB J5 COMI J6 COM2 J10 COM and J11 COMA 5 volts or 12 volts depending on jumper setting
147. d for Field Wiring TB See drawing P N DE 20782 If necessary see instructions in step 3 of Section 3 4 1 Modbus Slave Address COM ID Setup on page 30 2 Locate the DB BP fomale parallel printer port on the TB 1t is labeled 3 Use a standard parallel printer cable customer supplied for making the connection between the GC Controller and the printer s parallel port To connect a printer to one of the Controlle follow these steps serial COM ports 1 Access the GC Controller s Terminal Board for Field Wiring TB See drawing P N DE 20782 IE necessary see instructions provided in Section 3 4 1 Modbus Slave Address COM ID Setup on page 30 2 Choose an available serial port on the TB that is configured for RS 232 serial protocol Leave at least one serial port available for connecting the GC Controller to a PC usually COMI b Also leave available the other serial ports planned for use by RS 232 serial devices c See Section 3 4 4 CPU and COMAA Serial Communications Setups on page 45 for a complete listing of the TB s serial ports and their pinouts in order to prepare a serial printer cable 3 After the wiring connections have been completed use the MON2000 Software to configure the GC Controller s serial port for use by a printer a Select the Application gt Serial Ports menu path b Choose the serial port that correlates to the COM port chosen in Step 2
148. dem a Data Collection System DCS or a multi drop serial data highway network This Appendix is organized as follows GC Serial Port and Cable Configurations for RS 232 RS 232 Connection from GC Controller to PC DB 9 Serial Port of GC to DB 9 Port of PC DB 9 Serial Port of GC to DB 25 Port of PC Phoenix Plug Port of GC to DB 9 Port of PC Phoenix Plug Port of GC to DB 25 Port of PC RS 232 Connection from GC Controller to External Modem DB 9 Serial Port of GC to DB 25 Port of Modem Phoenix Plug Port of GC to DB 25 Port of Modem Example RS 422 Connection from PC to GC Example RS 485 Connection from PC to GC Jumper based Serial Channel Configurations GC SERIAL PORT AND CABLE CONFIGURATIONS FOR RS 232 This section provides more detailed information about the serial port connections of the GC Controller It identifies serial port pin assignments and diagrams for designing RS 232 serial cables if that is necessary for your application GC Serial Ports are found on the GC Controller s Terminal Board for Field Wiring and the connection points for external devices are as follows 2 Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatograph Table A 1 Serial Ports on the Terminal Board for Field Wiring G C Controller DEO plug connection Phoenix plug bare wire connecti Serial Port 1 COMD P2 3 Serial Port 2 COND P3 E Serial Port 3 COMS E Serial Port 4
149. diting follow these guidelines Move through menu Sell through the menu sequence to the desired data by items or data fields pressing ENTER after each corrector unchanged term or value Also use direction arrows Pressing ENTER without first entering data causes the Controller to skip to the next item View offscreen menu The menu displays eight lines Use the DOWN ARROW key to items move to submenu below the last item shown on a menu when necessary Goto particular menu To get into a particular menu scroll down to the menu and press item ENTER or press the number of the menu The menus work like a tree with the submenus branching far their particular fane Return to initial sereen Exit the editing procedure and save your changes by pressing the ESC key many times as necessary to return to the initial Save changes After editing changes completed press the ENTER or ESC key The query Write Changes 7 will appear Toggle the SPACE key to answer yes or no Press the ESC key to save any parameter changes and return to the preceding menu Press ENTER to save a changed or new item and move to the Editing Procedures 2010 Operation trom Local Keypad and Display 4 11 Model 500 Gas Chromatograph Correct a mistake T the wrong numeric key has been pressed during insertions press the BKSP key to back up and delete the item then enter The new value Move th
150. ditioning 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 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 uiv 2010 Sample and Gas Linos 330 gt Installation and Setup 3 4 INSTALLING THE GC CONTROLLER 3 4 1 Modbus Slave Address COM ID Setup Install Analyzer Wiring Install Analyzer Sample amp Gas L Install GC Controller Wiring Perform Leak Checks The GC Controller s COM ID is determined by dual inline package 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 DIP switch settings In most ca COM ID of 1 anel prewired or may not have had the COM ID s customer specifications tops in this 1 Change the GC Controller s COM ID or Follow th 2 Visually inspect and verify the COM ID as determined by the DIP switch settings only to GC systems that have not been shipped according to tion only if you wish to do the following Model 500 Gas Chromatagraph Instaling the GC Controller uiv 2010 Installation and Setup
151. e point to point full duplex interface allowing much longer cable runs than are possible than with RS 232 The differential transmitter and receiver twisted pairs offer a higher degree of noise immunity The following illustrations show the correct jumpering driver IC installation and UO connector pin definitions for each of the COMI channels when used in RS 422 mode cont peo PIN DEFINITIONS U2 Not installed BR H H US insted ipe US Instated NK Figure A 16 COMI DBS RS 422 CPU COM RS 422 Configuration RS 422 signal levels are supported on any or all serial channels with the installation of the optional Chip Kit P N 3 2350 115 This kit provides the driver ICs necessary for a single channel of RS 422 If two channels of RS 422 are required then two kits will be needed RS 422 is a 4 wire point to point full duplex interface allowing much longer cable runs than are possible than with RS 232 The differential transmitter and receiver twisted pairs offer a higher degree of noise immunity The following illustrations show the correct jumpering driver IC installation and I O Jumper based Serial Channel Configurations uty 2010 Model 500 Gas Chromatograph Supplemental Wiring Guide Serial Communications A 19 connector pin definitions for each of the COM2 channels when used in RS 422 mode COM DBO ji PIN DEFINITIONS s UO Not installed 1NA Bo U11 Instaled 2n U12 Instal
152. e actuations with those of the SPECTRUM chromatogram provided with the Operational Parameters Sheet uiv 2010 Analyzer Troubleshooting Guide 5 14 gt gt Maint Model 500 Gas Chromatograph Ensure that no evidence of component elutions is being injected present when no sample If differences exist between the two SPECTRUM chromatograms the problem may be due to one or more of the following Programming of events Contamination of valve sealing diaphragms by foreign matter Improperly adjusted flows Leaks in the carrier system Column deterioration due to liquid contamination from a sample Misidentifying peaks A noisy baseline can be eaused by carrier leaks an electronic failure in the Preamplifier a faulty power supply or defective thermistors in the detector If the baseline is still noisy after checking for leaks perform the Detector Bridge Balance procedure before replacing the detector thermistors or the preamplifier board Analyzer Troubleshooting Guide uiv 2010 Maintenance 5 15 Model 500 Gas Chromatograph Table 5 2 Analyzer Troubleshooting Checklist AS FOUND AS LEFT NOMINAL ANALYZER Leak check with SNOOP from carrier gaa bottle to Analyzer reg lator Leak check with SNOOP from calibration standard to auto cali bration solenoid Preamp balance voltage see par 26 av 0205 mV SAMPLE SYSTES Leak check with SNOOP
153. e cursor to an item and press the DEL key to delete an item Enter data for multiple After entering an item for example on stream one press NEXT streams to save the item and skip to the next sequence stream two Make time entries All time entries are in seconds to the nearest 1 10 second top analysis rans Press 5 GC Control and then 4 HALT to stop after the present the program during an analysis run from which dat Editing may cause analysis errors for that particular run Also do not attempt to edit or stop the Controller during a calibration sequence Calibration errors may result Get aferen saver To yet out of the screen saver mode press any key on the mode keypad No keys pressed during une hour will activate sereen saver mode Match entered data with When entering data a data identification tag will appear to the Data ID Tag right af the data box on the display to indicate the type of entry expected For details see Section 12 1 Editing Procedures on page 10 Press the ALT SPACE keys The ALI is used to toggle lista NSPACE key combination 4 2 5 Validity Checks of Data Entries The GC Controller compares each operator entry with preprogrammed ange and format requirements The Controller does not allow an unacceptable parameter to be entered such as an entry that is out of range or has wrong units e g letter instead of a number
154. e earrier gas line first according to the steps that follow 1 Purge the Analyzer Valves with carrier gas as follows a Open the carrier gas bottle valve and slowly increase the carrier gas feed line pressure to 115 pounds per square inch gauge psig 42 with the dual stage regulator at the carrier gas bottle je the Flow Panel of b Toggle each Analyzer Valve switch to OFF and ON positions about four to five times Analyzer Valve switches are in upper XJT box 2 Pressurize and check the carrier gas helium feed line as follows a Set all Analyzer Valve switches to the ON position b Open the carrier gas bottle valve and ensure that the carrier gas feed line pressure is 110 pounds per square inch gauge psig 42 c Shut the carrier gas bottle valve d Observe the pressure on the high side regulator gauge of the carrier gas bottle Because the MV vent line is plugged the pressure should not decrease during a period of 2 3 minutes e Set all Analyzer Valve switches to the OFF position Repeat steps 4 b through 4 4 g Set all Analyzer Valve switches to the AUTO position for regular operation 3 This complotes the carrier gas line leak check Next leak check the calibration gas feed line according to the steps that follow 4 Plug the Sample Vent labeled SV vent line Pressurize the calibration gas line to 50 psig Analyzer Troubleshooting Guide uiv 2010 Maintenance 4 5 21 Mode
155. e settings deseribed in steps 1 through 5 are maintained No other settings should be made 3 5 3 Purging ion Gas Lines Perform Leak Checks Purse Carrier Gas Lines 5 Purge Calibration Lines 10 StartUp GC System purge the calibration gas lines as preparation for first calibration follow these steps 1 Ensure that the carrier gas lines have been fully purged as described in the previous section 2 Close the calibration gas bottle valve 3 Fully open the block valve associated with calibration gas feed the block valve should be located on the SCS plate of the Analyzer 4 Fully open the metering valve on Flow Panel below the rotameter 5 Open the lower XJT box of the Analyzer Figure 3 28 to access the Valve Driver board Figure 3 30 6 On the Valve Driver board lower XJT box set the Stream switch to MAN if Stream 2 will be used for calibration gas 7 Open the calibration gas bottle valve 8 At the calibration gas bottle regulator increase outlet pressure to 20 psig 45 9 Close the calibration gas bottle valve 10 Lot both gauges on the calibration gas bottle valve bleed down to 0 zero psig 11 Repeat steps 7 through 10 five times uiv 2010 Purging Calibration Gas Lines 3 84 Installation and Setup Model 500 Gas Chromatograph 12 Open the calibration gas bottle valve 13 Regulate the flow through the rotameter
156. e the MON2000 Software for Gas Chromatographs User Manual PIN 3 9000 5221 This manual provides the following information Section 1 Description general description of the Model 500 gas chromatograph GC and its components their configurations and functions software user interface and A brief description of the Gt capabilities Introduction to GC theory of operation and terminology Section 2 Equipment Description Guidelines for sampling system and gas connections Descriptions of Analyzer subsystems and components Descriptions of GC Controller subsystems and components Section 3 Installation and Startup Instructions for installing the GC hardware Section 4 Operation Instructions for operating the GC by means of its built in keypad and liquid crystal display LCD if provided 12 115 116 1 1 7 12 Description Model 500 Gas Chromatograph Section 5 Maintenance Instructions for regular maintenance and care of the GC hardware Instructions for troubleshooting repair and service of the GC hardware Section 6 Recommended Spare Parts List of boards valves and other components suggested as spare parts Appendices Appendices with additional helpful reference materials and drawings 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 an
157. ect the 20 pin ribbon cable P N 3 2350 087 Rev C to the J6 connector on the CPU board 2 Plug the 10 pin connector labeled INTF J12 into the header labeled J12 on the system interface board for the serial port interface to the keyboard and display 3 Plug the 10 pin connector labeled INTF J8 into header labeled J8 on the system interface board for the interface to serial port 3 This will provide access to the COMS port on the field termination board is now dedicated for use as the serial port interface to the keyboard and display uiv 2010 Installing a Keyboard and Display without COM4A Board 6117 CPU to LX 800 CPU Upgrade instructions Model 500 Gas Chromatagraph 4 Start MON2000 and do the following a Select Serial Ports from the Application menu b Set the Usage for serial port 4 to Front Panel e Click OK The mode RS 232 RS 422 or RS 485 for all four ports can be set through MON2000 Installing a Keyboard and Display without COMAA Board 2010 Model 500 Gas Chromatograph 8117 CPU to LX 800 CPU Upgrade Instructions H 11 RETROFITTING THE ANALOG BOARD Model 2350 controllers shipped before late 1997 may have included 12 bit analog boards that are not compatible with the CPU boards sold as spares and in the 2350A upgrade kits These CPU boards require 16 bit analog board for proper operation Identifying your Analog Bo
158. ect the PC to the line driver 2 Connect the straight through serial cable from the PC s serial port to the RS 232 serial port of the line driver device Then connect the twisted pair cable to the RS 422 RS 485 serial port of the line driver 3 Configure the line driver for data communications equipment DCE operation See Appendix A for an example configuration of a Black Box brand model LD485A MP RS 232 RS 485 Multipoint Line Driver 4 Access the GC Controller s Terminal Board for Field Wiring TB If necessary sce instructions provided in Step 1 of Section 3 4 1 Modbus Slave Address COM ID Setup on page 30 Choose an available serial port on the TB that is configured for RS 4 RS 48 serial protocol and connect the twisted pair cable from the line driver See Appendix A for example connection Also see Section 2 44 CPU and COM4A Serial Communications Setups on page 45 for a list of ports and terminals assigned to serial communica tions When the unit has the Board installed COMS is used for uses COMA and it Controller PC Wiring Serial Connections Installation and Setup 3 45 Model 500 Gas Chromatograph 3 4 4 CPU and COMAA S 4 Communications Setups Install Analyzer Wiring Install Analyzer Sample amp Gas Lines Tostall GC Controller Wiring Perform Leak Checks The GC Controller has 3 to 8 serial communications po
159. ed 5 GND 7 RX 8 NIA 9 NA Figure COM RS 422 CPU COMS RS 422 Configuration RS 422 signal levels are supported on any or all serial channels with the installation of the optional Chip Kit P N 3 2350 115 This kit provides the driver ICs necessary for a single channel of RS 422 If two channels of RS 422 are required then two kits will be needed RS 422 is a 4 wire point to point full duplex interface allowing much longer cable runs than are possible than with RS 232 The differential transmitter and receiver twisted pairs offer a higher degree of noise immunity The following illustrations show the correct jumpering driver IC installation and VO connector pin definitions for each of the COMS channels when used in RS 422 mode n2 Ju PIN DEFINITIONS H rs U4 Not Installed 4 NA bo Bs U7 Installed im Us Instalod b 2 BER E Figure 4 18 COMS RS 422 2010 Jumper based Serial Channel Configurations A 20 Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatograph CPU RS 422 Configuration RS 422 signal levels are supported on any or all serial channels with the installation of the optional Chip Kit P N 3 2350 115 This kit provides the driver ICs necessary for a single channel of RS 422 If two channels of RS 422 are required then two kits will be needed RS 422 is a 4 wire point to point full duplex
160. efer Terminal 5 GND COM2 P22 COMS P23 COMB P24 COM 9 so reune sod bene Parallel Printer Interface Both the LX 800 and the 6117 CPU boards support a standard parallel printer port The parallel port connected via cable P N 3 2350 083 routes the signals from the CPU board to the System Interface Board uiv 2010 CPU and COM4A Serial Communications Setups 3 62 gt s Installation and Setup Model 500 Gas Chromatagraph The parallel printer cable customer supplied is connected to J1 on the Field Termination Board H E penal ECP confauralon jumpers J23 and J26 Figure 3 16 16 bit CPU board s Parallel Printer Port PC 104 Bus Interface Both the LX 800 and the 6117 CPU boards support I O expansion through the standard PC 104 Bus connectors at J19 and J20 The 6117 CPU board supports 8 bit and 16 bit PC 104 Bus modules the LX 800 CPU board supports 8 bit 16 bit and 32 bit PC 104 Bus modules The PC 104 Bus connector pin definitions are provided here for reference CPU and COMAA Serial Communications Setups JULY 2010 Installation and Setup 3 63 Model 500 Gas Chromatograph anm FE cT RESET B2 o 2 BD7 5 B30 806 g IRO9 Bio o A4 BDs ca MV B5 AS BDA DRQ2 B o A6 BD3 2 B7 o 802 aws BD Fa 12v B9 BDO GND 8105 o A10 IOCHRDY Co MEMW
161. efore all ohmmat Failure to do so may cause equipment damage OHMMETER CHECK MOVs MEMS Good Open or infinite hms Failed Shorted or 0 zero ohms Resistors RURE Gond 150 ohms NOT CONFIRMED IN TAB Failed Open infinite ohm short 0 ohms Diodes ZIZ Open infinite ohms in both directions Failed Short 0 ohms in any one or both directions TROUBLESHOOTING TRANSIENT PROTECTION MODULES JULY 2010 Model 500 Gas Chromatograph Guide to Transient Protection Modules c2 Table C 5 Troubleshooting TP PIN 2 2350 087 PIN 32250 027 16 pin Quad Bi dir Sngl That COMM 5 222 127 RS 485 VISUAL INSPECTION MOVs MIME Good Blue in colar Failed Diseolored to brown or black Resistors RI R4 Good Intact Failed Broken or open checks EQUIPMENT DAMAGE Remove transient protection module from board before hmm Failure to do so may cause equipment damage OHMMETER CHECK MOV MEMS Good Open or infinite ohms Failed Shorted or O zero ohms Rosistrs ERO Good 330 ohms Failed Open infinite ohms ar shart O ohms Diodes 70 Good Open infinite ohms both directions Failed Short 0 ohms in any one or both directions JULY 2010 TROUBLESHOOTING TRANSIENT PROTECTION MODULES C 8 gt Guide to Transient Protection Modules Model 500 G
162. egulators 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 Valuing 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 suty 2010 Sample Conditioning 24 Equipment description Model 500 Gas Chromatograph 2 1 6 Calibration Gas 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 LS 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 T
163. el 500 2 1 6 Calibration Gas 24 22 ANALYZER 25 2 2 1 Physical Description 25 22 2 Chromatograph Valves 27 2 2 3 Detector Subsystem 28 2 24 Analyzer Preampiifior Unit 29 2 2 5 Analyzer Specifications 29 2 16 Utility Gas Requirements 240 23 CONTROLLER 2 3 1 Controller Hardware Configurations 242 2 3 2 Optional Keypad and Display 2 25 2 3 3 Alarm Specifications 2 26 INSTALLATION AND 3 1 PRECAUTIONS AND WARNINGS SETUP 3 1 1 Hazardous Environments 34 3 12 Power Source Wiring 3 13 Signal Wiring 2 1 4 Electrical and Signal Ground 3 8 Electrical Conduit 3 1 6 Sample Systems Requirements an 3 2 PREPARATION 3 2 1 Introduction 342 3 12 Site Selection 313 3 2 3 Unpacking the Unit 344 3 24 Necessary Tools and Components 348 3 2 5 Optional Tools and Components 316 3 3 INSTALLING THE ANALYZER 3 3 1 Point to point Wiring Guide Analyzer Controller 338 Installation and Setup JULY 2010 Model 500 TABLE OF CONTENTS 3 332 333 34 344 342 344 345 346 3 4 8 35 352 353 36 OPERATION FROM 4 1 Analyzer AC Power Wiring 326 Sample and Gas Lines 227 INSTALLING THE GC CONTROLLER 330 Modbus Slave Address COM ID Setup 3 30 Controllor Analyzer Wiring 335 Controller PC Wiring Serial Connections 3 37 CPU and COMAA Serial Communications Setups 345 Controller Printer Wiring Discrete Digital 1 0 Wiring an Analog
164. ent offers maintenance service programs that are tailored to fit specific requirements Contraets for service and repair can be arranged by contacting the Daniel Measurement Services DMS a division of Emerson Process Management at the address or telephone number on the Customer Repair Report at the back of this manual There are also contact numbers and information available via www emersonprocese com daniel LOCATING AND GAINING ACCESS TO EQUIPMENT ELEMENTS Analyzer Electrical Electronic Units The electrical electronie units of the Analyzer except for the detector and heater elements are located in the upper and lower explosion proof housings of the Analyzer and are fully accessible from the front of the unit Printed circuit assemblies are contained inside an explosion proof housing accessible by removing a threaded cover plate from the housing front See Figure 5 1 uiv 2010 Routine Maintenance Procedures 5 5 3 Maintenance Model 500 Gas Chromatagraph SERIOUS PERSONAL INJURY OR DEATH POSSIBLE The explosion proof housing should not be opened when the unit is exposed to an explosive environment If access to the explosion proof housing is required precautions must be taken to ensure that an explosive environment is not present Failure to observe all safety precautions could result in serious injury or death Yemen Tree o Quis rote cenet SNP RS ae seken Set fone anus mmm
165. 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 ean be enclosed in an electric heat tape design oven 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 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 how
166. epeat the procedure with sample gas and stream gas after first shutting the metering valve below the rotameter on the front of the Flow Panel The metering valve is left shut for now but will be reopened later during initial purging and the Analyzer s first calibration suty 2010 Analyzer Leak Checks 3 80 gt Installation and Setup Model 500 Gas Chromatagraph 3 5 2 Purging Carrier Gas Lines Perform Leak Checks Purge Carrier Gas Lines Purge Calibration Lines 19 San Up GC System EQUIPMENT DAMAGE OR PERSONAL INJURY Purging carter and calibration gas lin be tumed on to the Analyzer Ensur all external signal connections have rounds have been made will requiro that AC power that unit interconnections and verified and proper Failure to verity all connections may result in equipment damage or personal injury Tubing should be clean and dry internally During installation use compressed air to remove moisture dust or other contaminants from all tubing purge the carrier gas lines as preparation for first calibration follow these steps 1 Ensure that the MV vent line plug has been removed and the vent line is open 2 Turn ON the AC power to the Analyzer With AC power turned ON and the upper XJT box open the green LED by the Column Heater label should now be illuminated See Figure 3 28 and Figure 3 29 Purging Carrier G
167. er see drawing CE 10492 Analyzer drawings addendum of this manual 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 Installation and Setup 3 27 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 electrical power to the Analyzer or the GC Controller until 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 3 3 3 Sample and Gas Lines Install Analyzer Wiring Install Analyzer Sample amp Gas Linea Install GC Controller Wiring Perfor
168. er IC s The configuration options for each of the supported modes are shown on the following pages E COM and COM 4 output header E 3 mes Figure A 11 CPU Configuration uiv 2010 Jumper based Serial Channel Configurations 16 5 Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatograph CPU RS 232 Configur CPU COMI RS 232 Configuration COMI is I O mapped at 3F8H and utilizes a 16550 type DART contained in the Super chip When used in RS 232 mode COMI is terminated via the Multi UO connector at J1 The configuration details and the pin definitions when used with the cable P N 3 2350 083 are shown her COMI DBO PIN DEFINITIONS U2 Installed 1 DCD Not In 2 RX Data US Not Installed 2 RX Dein U6 Not Installed DIR Figure COMI RS 232 CPU RS 232 Configuration COM is 1 0 mapped at 2F8H and utilizes a 16550 type UART contained the Super LO chip When used in RS 232 mode COM is terminated via the multi I O connector at J1 The configuration details and the pin definitions when used with the cable PIN 3 2350 083 are shown here comz DBO PIN DEFINITIONS UO Installed 4 pep UN Not Installed X Dali be Ur2 Not Installed 1079 Figure A 15 Jumpar based Serial Channel Configurations JULY 2010 Supplemental Wiring Guide Serial Communications A 17 Model 500 Gas Chromato
169. er Number HE System Parameters As Found AsLeft Nominal Carrier Gas Cylinder Cylinder Pressure Reading High psig psig Cylinder Pressure Outlet Reading psig psig Carrier Pressure Panel Regulator veis NA SS psig Sample System Sample Line Pressure CD mig pel 20psig pig psig 20peig T psig T psig 20psig 6 pig psig 20 psig Sample Flows cemin 40 60 ce 40 60 ce sein cemin 40 80 ce O 40 60 ce 5 emin cemin 40 60 ce Calibration Gas High Pressure Reading psig psig Outlet Pressure Reading psig psig 20psig Flow comin emin 40 60 ce Model 500 Maintenance Checklist suty 2010 Model 500 Gas Chromatograph 522 523 53 534 Maintenance 5 5 Routine Maintenance Procedures 1 Complete the Model 500 Maintenance Checklist bi monthly Place the sales order number date and time on the form and file it This gives you a basis for comparison in the future if you need it 2 Save Chromatogram of the operating Analyzer on the PC with MON2000 Print configuration calibration and raw data reports and file them with the Maintenance Checklist Also upload the current application to the PC with MON2000 3 Check the printer paper roll if used to ensure that a sufficient supply of paper remains Check carrier and calibration gas supplies 4 There is no routine maintenance to be performed on the GC Controller Contract Service Emerson Process Managem
170. ere rc a mun NE CARI zt SEED Sic eme 6 ria saame EMERSON Da SERR stc owes v pa seco oria eee ree oo pE 18301 D MI TIC E Gr WE fea E P m NOTES 1 ALL CUSTOMER CONNECTIONS ARE 1 8 SWAGELOK TUBE FITTINGS UNLESS NOTED SAMPLE VENT SOLENOID WIRING 4 IS LOCATED IN THE LOWER ELECTRONICS ENCLOSURE BEHIND THE VALVE DRIVER BOARD REF DE 10493 CAL STD SL 1 TB4 53 54 STREAM 1 LEGEND S C S PLATE FILTER INLINE 1 8 1 V 3 4 5000 202 VALVE REG 1 8 1 FI 1 4 5000 122 FLOW IND 0 100 ccm 1 sl 1 4 5000 075 SOLENOID VALVE 3 WAY WORK IT SHALL NOT BE REPRODUCED AND SHALL BE RETURNED TO US ON DEMAND ALL RIGHTS ARE RESERVED THIRD ANGLE PROJECTION C l y y GEDUETRC TOLERANCES amp DIMENSIONS PER ANSI 14 5 amp 11 29 05 HM ECO XX 5001321 LATEST REVISION HM S C S PLATE 5 3 05 ECO XX 5000713 mess wa EMERSON 1 STREAM WITH N A 12 92 AH ECO 7882 Ex ine Process Management AUTOCAL 7 92 AH RELEASED E DRN HAYSLIP DATE 7 28 92 DG NO N A REV DATE DRN DESCRIPTION CHKD len AT Gn asup wt 7 28 92 16120 0 a Bone PROJ FILE NO NONE FILENAME CE16120D1 DWG DATE 11 29 05 TIME 8 16 AM RH Ne 7 92 Ents SEE ORDER 151 oF 1 2 8 oy ia mes sS iR du Prius ANAL
171. erews that secure the TB Then unplug the TB from its connections at the back top of the board 4 Lower the TB down and out of the way held in place by its ground straps at the bottom of the board This exposes the Card Cage Assembly Loosen the four screws that secure the Card Cage Assembly to the chassis Then remove the Card Cage Assembly away from its chassis mount so that it is easy to work on 8 Locate the System Interface and Driver board It is mounted to the top of the Card Cage Assembly a Disconnect the Analog cable from J6 on the System Interface Board then disconnect all CPU cables from the System Interface Board b Remove the CPU assembly and install the COM4A Board with associated mounting hardware to J19 and J20 PC 104 Bus connector on the CPU assembly Connect COMS P22 and COME P23 on the Field Termination Board via cable PIN 3 2350 085 to J6 on d Connect COM P24 on the Field Termination Board and COMS via cable PIN 3 2350 086 to J3 on e Install the CPU assembly into the third slot of card cage Connect the CPU cables as detailed in Section BASIC 2350A CONFIGURATION on page 7 Install the DB9 connector from COMS to P22 on the Field Termination Board with jackpost assemblies The COM A Board 2010 2350 to 2350A CPU Retrofit Instructions G 11 Model 500 Gas Chromatograph g Install the DB9 connector from COMS to P23 on the Field
172. es are the number of spares that is normally adequate to cover most contingencies at facilities where a larger number of GC Systems are in operation The minimum quantities are the number of spares at facilities with only a few GC Systems Daniel Measurement Services DMS a division of Emerson Process Management offers service and repair service contracts that make maintaining most spares for the GC System unnecessary Details regarding Daniel Measurement Services contracts may be obtained by contacting the Daniel Measurement Services Service Department at the address or telephone number on the Customer Repair Report in the back of this manual ANALYZER SPARES Printed Circuit Card Assemblies Analyzer Description Part Number Maximum Minimum Preamplifier assembly 0500201 1 1 Temperature control assembly 20800202 1 1 Decoder assembly 0500 200 1 1 Valve driver assembly 0500 178 1 1 6 1 2 Electrical and Mechanical Assemblies Analyzer Description Part Number Maximum Minimum Allenair 4 Way solenoid valve 4000 369 1 1 SCO 3 Way solenoid valve Auto Cal _ 45000015 1 valve repair kit port valve 39800 108 3 1 Carrier gas regulator n 1 6 2 gt Recommended Spare Parts Model 500 Gas Chromatagraph Description Part Number Maximum Minimum Temperature control thermistor 30500 103 1 Thermistor seal 6 s Thermistor set OK Gey 1 1 Microfuse 3A
173. ess the ENTER key to accept the default Yes option Or to return to the GC Control submenu without beginning an auto sequence analysis press the ESC key 5 The green LED indicator will illuminate to show the GC is running an analysis To see the progress of analysis runs press the ESC key to return to the Main Menu sereen then press the ESC key again to exit from operator control of the GC System The status screen will appear and next to the RUN field a number is displayed The number increases periodically to indicate the seconds elapsed since the beginning of the current analysis halt ongoing analvsis runs proceed as follows 1 In the GC Control submenu press the 4 key to select Halt 2 At the Halt Write Changes prompt press the ENTER key Or to return to the GC Control submenu without halting analysis runs press the ESC key uiv 2010 Start Halt an Auto Sequence Analysis 4 10 7 Operation from Local Keypad and Display Model 500 Gas Chromatagraph When analysis runs are halted at the end of the current analysis eyele the green LED indicator will no longer be illuminated Stop Now instead of Halt it forces the system to idle This may allow components to continue to elute from the columns Therefore it is recommended you choose Halt instead of Stop Now A Halt command stops analysis runs after the current run is finished 4 2 4 Editing Procedures For e
174. ever this method offers more limited functions Display of the chromatograms on the LCD is accomplished in serolling 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 uiv 2010 INTRODUCTION lt 1 4 Description 1 Model 500 Gas Chromatograph FUNCTIONAL DESCRIPTION A functional block diagram of a typical Model 500 Analyzer installation is shown in Figure 1 1 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
175. fied 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 1 713 827 5314 This page is intentionally let blank DESCRIPTION EQUIPMENT DESCRIPTION TABLE OF CONTENTS xm 13 15 1 8 1 7 42 5 2 5 3 16 244 242 244 244 245 PURPOSE OF THIS MANUAL Section 1 Description Section 2 Equipment Description Section 3 Installation and Startup Section 4 Operation Section 5 Maintenance Section 6 Recommended Spare Parts Appendices INTRODUCTION FUNCTIONAL DESCRIPTION MODES OF OPERATION User Interfaces Capabilities THEORY OF OPERATION The Analyzer Detector Data Acquisition Peak Detection Basic Analysis Computations GLOSSARY SAMPLING SYSTEM Sampling Point Location Sample Volume and Flow Rate Sample Conditioning Contamination Precautions Valving 1a 12 12 2 aa E 16 185 aa ad 140 am 112 22 22 23 ET 23 2 gt TABLE OF CONTENTS Mod
176. from the System Interface Board b Remove the CPU assembly and install the Ethernet assembly with associated hardware into J19 and J20 PC 104 Bus connector on the CPU assembly If an option board is already plugged into the PC 104 Bus on the PC T04 Bus connector an the option board e Plug one end of the Ethernet extension cable PIN 3 2350 088 into J5 of the Ethernet assembly The in line jack on the remaining end of the Ethernet extension cable attaches to the lower left inside wall of the card cage shield after the CPU assembly is reinstalled and all cables reconnected to the System Interface Board No software setup is required for this board d If the 2350A BOS version is v1 84 or later ensure that J6 Jumper on pins 13 14 of J1 has been removed See Figure G 9 and Figure G 10 an 2 I3 6 5 10 TWEE 2022342525 E 3 5 3 7 9 1119151719 21232527 Figure G3 Ethernet Jumper Configuration BOS v1 82 and Earlier TO ADD AN ETHERNET CARD JULY 2010 2350 10 2350A CPU Retrofit Instructions 6 17 Model 500 Gas Chromatograph a d EG 6 Z 10 T2 12 18 2022222625 8 1 3 9 75 113151719 2123252 Figure G 10 Ethernet Jumper Configuration BOS v1 84 and Later I an option board is installed on the PC 104 Bus on the CPU install the Ethernet Board and mounting hardware on the PC 104 Bus connector on the option
177. g Check all fittings at the pressure regulator flow panel and at the carrier gas cylinder regulator with a leak detector Correct any leaks detected by a bubble indication Turn the carrier gas cylinder shut off valve clockwise to close Observe the carrier gas pressure for ten minutes to check for a drop in carrier pressure The drop should be less than 200 psig on the high side of the regulator gauge If the carrier gas pressure remains constant no leaks are present Actuate the VALVE ON OFF switches and observe the pressure with the valves in different positions than in step 4 When the valves are Analyzer Troubleshooting Guide suty 2010 Maintenance 5 17 Model 500 Gas Chromatograph switched some pressure change is normal because of carrier loss Momentarily open cylinder valve to restore pressure if necessary 6 Ifthe pressure does not hold constant check all valve fittings for tightness 7 Repeat step 5 again 1 leaks persist check the valve ports with a commercial Helium leak detector Do not use a liquid leak detector on the valves or components in the upper Analyzer oven within the black insulated cover perform a factory level leak check of the Analyzer follow these steps NOTICE The following are steps performed to leak check the Analyzer at the factory when the Analyzer is quality checked prior to This procedure is more thorough and is designed to zon of the Analyzer where a leak
178. graph 4 1 INTERFACE COMPONENTS FOR LOCAL DATA DISPLAY AND ENTRY The components for local data display and entry are the light emitting diode LED indicator lights the liquid erystal display LCD and the built in keypad DISPLAY r Yeuuow GREEN L RED Figure 4 1 LED Lights LCD and Keypad for Local Data Display and Entry 4 1 1 Light Emitting Diode Led Indicators There are three colored status indicators on the GC Controller that show the gross status of the total system Table 4 1 summarizes the condition indicated when these indicators are illuminated Table 4 1 Conditions Indicated by the GC Controller s LED Status Indicator Lights YELLOW The GC has an unacknowledged alarm s GREEN The Controller is currently running an analysis RED The GC isin RUN mode and has an out oftolerance or alarm condition that requires an operator action 2010 INTERFACE COMPONENTS FOR LOCAL DATA DISPLAY AND ENTRY 44 Operation from Local Keypad and Display Model 500 Gas Chromatagraph 4 1 2 4 1 3 Liquid Crystal Display LCD The LCD measures 5 5 x 2 inches and is capable of 64 by 256 resolution with full graphics It is certified for use with an explosion proof NEMA AX 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
179. graph CPU COM3 RS 232 Configuration COM3 is 10 mapped at and utilizes a 16550 type UART contained in the 16C532 companion chip When used in RS 232 mode COM3 is terminated via the connector at J6 The configuration details and the pin definitions when used with the cable P N 3 2350 087 are shown here 312 14 U4 Installed Wm m Ur _ No Red BB SE Figure 4 14 COMS RS 232 CPU RS 232 Configuration is I O mapped at 2 and utilizes a 16550 type UART contained in the 16532 companion chip When used in RS 232 mode is terminated via the connector at J6 The configuration details and the pin definitions when used with the cable PIN 3 2350 087 are shown here PIN DEFINITIONS alls n U10 Installed 1 DCD T To U13 Not installed 2 RXDATA U14 Not Instaled 3 MA 90 8 SSR Hi RH SR Figure A 15 COME RS 282 suty 2010 Jumper based Serial Channel Configurations A 18 5 Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatograph CPU RS 422 Configuration CPU COMI RS 422 Configuration RS 422 signal levels are supported on any or all serial channels with the installation of the optional Chip Kit P N 3 2350 115 This kit provides the driver IC s necessary for a single channel of RS 422 If two channels of RS 422 are required then two kits will be needed RS 422 is a 4 wir
180. h Equipment description 2 21 The inserted circuit boards of the GC Controller perform these functions Table 2 2 Functions of Inserted Circuit Boards GC Controller Card Cage Assembly Handle Label EMEN See drawing Subsystems or Part Number Function number rbi CPU TXson Microprocessor control of DE20782 microprocessor board 16bit CPU microprocessor board MCM LPM 6117 parallel printer port control of COMI COM2 and communication ports system memory RS 422 serial protocol three timers digital UO and CompactFlash Additional memory for higher capacity data archives Board CPU Daughter board Control of COMG COMS BE20767 CPU daughter board Modem CPU Telephone modem NA Daughter board Analog VO board Analog Control of eight analog inputs BE 18044 4 for user applications and 4 requires for Analyzer Controller inter MON2000 connect and two six or ton software version analog outputs 23 or later Ethernat Card PCM NE 2000 Flexible high performance N A networking capability broad spectrum of software support 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 the
181. handled The following precautions must be observed when working with the assemblies Do not install or remove the Model 500 Analyzer printed circuit assemblies or the GC Controller printed circuit assemblies while power is applied to the units Keep electrical components and assemblies in their protective conductive carriers or wrapping until ready for use Use the protective carrier as a glove when installing or removing printed circuit assemblies suty 2010 Detector Elements Hester Elements Valves and Columns 5 8 Maintenance Model 500 Gas Chromatagraph Maintain contact with a grounded surface to prevent static discharge when installing or removing printed cireuit assemblies 5 5 SERVICE TROUBLESHOOTING AND REPAIR INSTRUCTIONS This section contains service troubleshooting and repair information for the Analyzer The information is arranged as appropriate either by major subsystems or by major functions of the instrument Table 5 1 refers you to more frequent possible causes for the hardware alarms Correct ALL alarms before recalibrating Table 5 1 Alarms and Possible Causes ALARMS POSSIBLE CAUSES 1 Application Checksum Failure Disk on Chip RON Checksum Failure Disk on Chip RAM Diagnostics Failure Tad RAM Preamp Input 1 Our of Range rior gas gone air not purged from carrier lines power failure bad thermistor preamp out of balance or fai
182. he Condulet Cover is the Valve Driver Board then TB 4 4 With the Condulet cover removed loosen and remove the four 4 thumbserews that hold the Valve Driver board 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 Pointtc point Wiring Guide Analyzer Controller uiv 2010 Installation and Setup 3 21 Model 500 Gas Chromatograph los E iro ee Figure 3 4 Valve Driver Board Resting Face Down from ita Cable Allows Acces to TB 4 uiv 2010 Point to peint Wiring Guido Analyzer Conuolier 322 gt s Installation and Setup Table 3 1 Model 500 Gas Chromatagraph and GC Controller Interconnect Leads Hoard Acronyms Interconnect Terminal Hoard of Analyzer Terminal Board for Field Wiring at Controller TB Analyzer eae Controller Terminal 11 Function code 1 19 Terminal 1 Terminal 12 Function code 2 118 Terminal Terminal 13 Function code 4 119 Terminal 3 Terminal 14 Function code 8 Terminal 4 Terminal 15
183. i Bomo EU na niti w uos Harem aeons uw 8 8 wa el se mena weg ee mua E ETE cr 20766 f rura me nsa RE N E 1237 Pk TEE eu besser Dr mmm Tui coms coms 7 coms come cou come 2350A COM4A COMMUNICATION PORT CONFIGURATIONS IC PLACEMENT SET FOR RS 22 SET FOR ASAE SET FOR RSF CINSTALLED NOTINSTALLED C INSTALLED NOT INSTALLED Us UU USUS T 7107075 US E 0107017 Toure 715 Um T 057012 T 107 5 JUMPER PLACEMENT D EG res x e E S E ore s a ufar meses EMERSON cous stat m fences mre meris Management 380A CONTROLER c ucc ST aje 8 5 0 ee E n a sm pw seems oro ape car esp E BET Co 20766 d mu vee nua CENT ies ONE ME TEST Pa Lue emu peus Fans T PIX a E SLATES AN ser Jumpers as ip T HEET 2 122 im lg DELETED PER ECO XX SODS18S LOAD THE LATEST VERSION OF UNOS REPRESENTED BY XXX HERE THE COMPACT FLASH MEMORY REFERENCE 2 8 2350 351 ATTACH BRADY LABEL TO THE BACK OF THE BOARD WITH FOLLOWING P N 2 3 2350 140 2390 CMOS
184. ield Wiring TB If necessary see instructions provided in Step 1 of Section 3 4 1 Modbus Slave Address COM ID Setup on page 30 2 Choose an available serial port on the TB that is configured for RS 232 serial protocol NOTICE Unless specified otherwise by customer order all versions of the Controller aro configured by default from the factory for RS 232 For the Rack mount retrofit and explosion proof versions of the GC Controller and serial channel COMA Is Used for the keypad and display without the Board With the Board installed COMB is used for the keypad and display For further details see Section 3 4 4 and drawing DE 20782 GC Controller drawings addendum The easiest option is to use a straight through serial cable like the one described for the GC Controller front panel connection see PC to GC Front Panel Quick and Easy RS 232 on page 40 and connect it to either one of the DB 9 female jacks on the TB Another option is to use a Direct Serial Connect Cable P N 3 2350 068 or fabricate one like it Connect the DB 9 female plug end to the DB 9 male serial port on the PC Connect the cable s exposed leads to the GC serial port on the TB When the DB 9 female plug of the cable is connected to a standard PC its six leads will be configured for RS 232 as shown in Table 3 3 Controller PC Wiring Serial Connections suty 2010 Installation and Setup
185. in changes It may be viewed in color as it i processed on a PC VGA display Tick marks recorded on the chromatogram by the GC Controller indicate where timed events take place 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 electrie 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 2010 Description 1 17 Mode 500 Gas Chromatograph Response Faetor Correetion faetor 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
186. in 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 J OPTIONAL MODEM CARD NAY BE INSTALLED INSIDE CONTROLLER tocar pensers ANO pos caor Be URED A GARE EIRORERT mene 2251 RETROFIT KIT 18 AVAILABLE h g OPTIONAL EQUIPMENT Figure 1 1 Model 500 Analyzer Punetional Block Diagram uiv 2010 FUNCTIONAL DESCRIPTION 16 14 144 142 Description Model 500 Gas Chromatograph MODES OF OPERATION 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 PIN 3 9000 522 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 This feature is optional on all standalone models of the GC except the portable Compact BTU GC Capabilities
187. indicators are located at the side of the display on the front panel The indicators are arranged from yellow green and ved 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 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 re entered before the Model 500 program can be changed Red LED When illuminated the Red LED indicates an out of tolerance 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 suty 2010 Equipment description 2 27 Model 500 Gas Chromatograph This page is intentionally left blank JULY 2010 Alarm Specifications 2 28 Equipment description Model 500 Gas Chromatograph
188. indow 5 8 5 Performing an Automated Calibration To perform an automated analog output calibration from the Analog Outputs dialog box 1 Use the Application gt Analog Outputs menu path to access this function 2 The Analog Outputs dialog box appears scam x me 3 Select the desired analog output by clicking anywhere in the corresponding row 4 Click on the AutoCal button or press the F8 key You can abort this process at any time by clicking on the Caneel button uiv 2010 Performing an Automated Calibration 5 40 gt Maintenance Model 500 Gas Chromatograph 5 The Zero Scale Adjustment dialog box appears Current device value on engineering units Input the appropriate value and click on the OK button determine the uncalibrated Zero Scale and Full Scale analog output levels see Section 5 8 1 6 The Full Seale Adjustment dialog box appears Current device value on engineering units Input the appropriate value and click on the OK button To prevent scale adjustment set both adjustment values to zero 10 0 7 Ifthe values entered are within tolerance data in the zero and full adjustment columns is updated Otherwise MON2000 displays an error message Performing an Automated Calibration JULY 2010 Maintenance 5 41 gt Model 500 Gas Chromatograph 5 8 6 Analog Loopback Test Circuits External loopback test circuits ea
189. ion proof GC units may result in noncompliance equipment damage or personal injury lations when installing explosion proof Hazardous Environments 2010 Installation and Setup lt 3 5 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 1 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 1 Observe Precautions and Warnings Location 2 Paw Obtain Supplies and Tools Install Analyzer Wiring Follow these precautions when installing AC power source wiring to the Model 500 Analyzer and the GC Controller instru mentation 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 install
190. ith DB 25 serial port you will need to manufacture the cable and its DB 25 male plug cable end as illustrated below see Figure A 8 DE y k 22 RI out 5 CTS out 6 DSR out 7 GROUND 2 THO nj 3 RD out Male DB 25 plug for connecting Phoenix Pug to external modems seria port Figure 8 GC Phoenix Plug Port to External Modem DB 25 Port uiv 2010 Phoenix Plug Port ot GC to DB 25 Port of Modem 5 Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatograph AA EXAMPLE RS 422 CONNECTION FROM PC TO GC This section demonstrates an example RS 422 connection from a PC to GC that is accomplished through use of an asynchronous line driver interface device The line driver device serves as an interface between the RS 232 output of the PC and the RS 422 protocol needed for long distance serial input to the GC Specifics of the line driver are as follows Black Box brand model LD485A MP RS 232 RS 485 Multipoint Line Driver RS 232 input to connect to the PC and RS 422 or RS 485 output to connect to the GC RS 422 line terminations are illustrated in Figure A 9 below and jumper and switch settings to configure the line driver device are listed in Table A2 next page NOTE For this example a straight through RS 232 serial cable is used to connect between the PC and the line driver GC Controler Black Box L
191. k on the desired variable to select it sae cor scr EO ane Biss BT act Weil vaus Na ETU D entra vaue sa Hata al Nat ETU Ae Weetravaue sup rsp Hearne animu sa Head vaus Sie ns at Hes aie Myra Dr vane Se ag 3 Click on the OK button to accept your changes and return to the Analog Outputs dialog box Click on the Cancel button to abort and return to the Analog Outputs dialog box Changing the Bargraph JULY 2010 Maintenance 5 37 Model 500 Gas Chromatograph 5 8 4 Performing a Manual Calibration 1 Use the Application gt Analog Outputs menu path to access this function 2 The Analog Outputs dialog box appears tosya scam x cem Select the desired analog output by clicking anywhere in the corresponding row 4 Set the Zero Seale and Full Scale values as desired 5 Set the Fixed Var parameter to Fixed 6 Set Fixed Value equal to the Zero Scale value 7 Set Zero Adjustment and Full Adjustment to 0 0 Setting both adjustment val adjustment s to 70 0 di the scale uiv 2010 Performing Manual Calibration 5 38 gt gt Maint Model 500 Gas Chromatograph 8 Click OK to accept your changes and exit from the Analog Outputs dialog box 9 Return to the Analog Outputs dialog box Wait until the Current Value of the analog output is equal to the Zero Scale value see Step 10 Record the v
192. l 500 Gas Chromatograph Calibration gas line pressure of 50 psig is for leak check and test a Shut the calibration gas bottle valve b Observe the pressure on the high side calibration gas bottle Because the SV vent line is plugged the pressure should not decrease during a period of 2 3 minutes gulator gauge of the 6 This completes the calibration gas line leak check Next leak check the sample gas lines according to the steps that follow 7 Plug the SV vent line it may already be plugged if you performed stops through 7 above to leak check the calibration gas lino Pressurize the sample gas line to 50 psig or a known pressure Sample gas line pressure of 50 psig is for leak check and test purposes only For normal operation sample gas line pressure is maintained at 20 20 psig Shut off the sample gas b Observe the pressure on any gauge that indicates pressure between the closed sample gas block valve and the plugged SV vent line Because the line is plugged the pressure should not decrease during a period of 2 3 minutes 9 Leak test all other sample stream lines by connecting gas to each of the sample streams and repeating steps 9 through 10 b uiv 2010 Analyzer Troubleshooting Guide 522 Model 500 Gas Chromatograph 555 10 Finish the test and set up the Analyzer for normal operation as follows a Ensure that all Analyzer Valve s
193. lanced 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 Tho Analyzer Detector JULY 2010 Description lt 1 9 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 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 ta a 4 to 2
194. lating 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 suty 2010 Model 500 Gas Chromatograph 233 234 245 Equipment description lt 2 3 the sample line is set at 50 cubic centimeters ce 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 ce of volume per foot Therefore with a flow rate of 50 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 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 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 r
195. led Analyzer temperature interconnection wiring control power supplies 5 Preamp Input 2 Out of Range Same as number 6 Preamp Input 3 Out of Range Same as number Preamp Input 1 Out of Range Same as number Preamp Failure Same as number Analog Output 1 High Measured value program fur output 1 greater than operator defined full scale range 10 Analog Output 2 High Same as number 0 Analog Output 3 High Same as number 0 12 Analog Output 1 High Same as number 0 13 Analog Output High Same as number 9 SERVICE TROUBLESHOOTING AND REPAIR INSTRUCTIONS suty 2010 Model 500 Gas Chromatograph Maintenance 5 9 ALARMS 14 Analog Output 6 High Same as number 9 15 Analog Output 7 High Same as number 9 16 Analog Output 8 High Same as number 9 Analog Output 9 High Same as number 9 18 Analog Output 10 High Same as number 97 19 Analog Output 1 Low Measured value program for output lower than operator specified zero range 20 Analog Output 2 Low Same as number 19 21 Analog Output 3 Low Same as number 19 22 Analog Output 4 Low Same as number 19 25 Analog Output 5 Low Same as number 19 24 Analog Output 6 Low Same as number 19 25 Analog Output 7 Low Same as number 19 26 Analog Ou
196. ligent and or non compliant with applicable requirements EQUIPMENT DAMAGE OR PERSONAL INJURY The responsible body shall operate the equipment as designed and specified by the manufacturer Failure to do so may caus equipment personal injury or damage to the uiv 2010 Precautions and Warnings 34 Installation and Setup Model 500 Gas Chromatagraph 344 Hazardous Environments Cheers Praia oad Warnings Plan Site Location Obtain Supplies and Tools stall Analyzer Wiring Follow these precautions if installing or operating the Model 500 Analyzer and the GC Controller instrumentation in a hazardous 1 Install and operate only the explosion proof version of the GC Controller in a hazardous area 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 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 GC units Failure to observe all regulations when installing explos
197. lows 1 Attach a flow meter to the vent output on tho left side of the Analyzer marked MV 2 The flow should measure 12 18 co min 5 5 9 Analog Inputs The analog inputs available to the GC Controller from the Model 500 Analyzer and external analyzers are shown in the following tables See also drawing DE 20782 in Addendum 2 GC Controller Drawings this manual Table 5 3 Analog Inputs to GC Controller from Analyzer Board Acronyms Terminal Board for Field Wiring at Controller TB RIPREAMPLIFIER SIGNAL OUTPUTS from ANALYZI R erminal 11 common ermina 1 120 mA Gain channel 1 861 Measure between terminals 10 and 20 18 TB J18 Terminal 4 20 mA Gain channel 2 6 Measure between terminals 9 and 50 at ET ferminal 420m Gain channel 3 8x32 Measure between terminals 5 and a us 0 mA Gain channel 4 8x256 Measure between terminals 1069 and 110 at TB J18 uiv 2010 Measure Vent Flow MV 5 28 gt gt Maintenance Model 500 Gas Chromatagraph Table 5 4 Analog Inputs to GC Controller from User Devices Board Acronyms Terminal Board for Field Wiring at Controller TID TB J12 Terminals 123 20 mA common shield Analogin 1 TB J12 Terminals iS 20 mA common shield TB J12 Terminals 789 4 20 mA common shield Analogin 3 TB J12 Te
198. m 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 line flow clean air or gas through them Blow out internal moistu dust or other contaminants uiv 2010 Sample and Gas Lines 328 gt Installation and Setup Model 500 Gas Chromatagraph 1 Remove the plug from the Analyzer Sample Vent SV line 1 16 inch tubing marked SV located at left side of Analyzer in the installation the Analyze sd MV is left plugged until Analy completed For regular Analyzer operation however the MV line must be unplugged or open HINT Do not discard the vent ine plugs They are useful at any ime when leak checking the Analyzer and its sample or gas line connections If desired connect SV vent line to an external ambient pressure vent Ifthe 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 Connect carrier gas to Analyzer DO NOT TURN ON GAS AT THIS TIME NOTICE See Appendix B this manual for a description of a dual cyinder carrier gas manifold PIN 3 500 050 with these featur Carrier gas is fed from two bottles When one botti ly empty 100 psig the other bottle becomes the primary supply Each bottle can
199. may occur 1 Plug the Measure Vent labeled MV vent line The SV or Sample Vent line should be left open or unplugged 2 Access the upper explosion proof box QUIT of the Analyzer so that you will be able to manually operate the analyzer valve switches located on the switch panel inside the box a See Figure 5 2 for an illustration of the Analyzer XJT box locations uiv 2010 Analyzer Troubleshooting Guide 5 18 gt Maintenance Model 500 Gas Chromatagraph b See Figure 5 3 for an illustration of the Analyzer Valve Switches upper XJT Upper XIT Box Analyzer Valves ESI Columns Detectors Presmetter Heater and Up oe 7 fand temp controler ws Analyzer valve switches Flow Panel Lower XP Box Lower XIT Box Power supply ses Terminal board Mounting Sample system valve te river board ANALYZER Figur 5 2 Location of Analyzer XJT Bases Analyzer Troubleshooting Guide suty 2010 Maintenance 5 19 Model 500 Gas Chromatograph COLUMN HEATER DETECTOR HEATER O ANALYZER VALVE 1 O 19 BRIDGE BALANCE le 5 59 ADJUST BRIDGE BALANCE ANALYZER VALVE 2 O ANALYZER VALVE 3 O Figure 5 3 Analyzer Valve Switches Upper XJT uiv 2010 Analyzer Troubleshooting Guide lt 5 20 gt gt Maintenance Model 500 Gas Chromatograph Leak check th
200. minal 1 NC P23 COME s Terminals Boor sD a Terminal 3 Six RxD Terminal a D5 e Terminals GND seet nrbe Terminal 6 NOTE DES Terminal plug on GC f aller ls wired Terminal S to eliminate the need for a null modem cable between the anda PC Terminal 9 Rr RS 422 Configuration Ports Maximum number of RS 42 Controller Printer Wiring ports available five see Section 3 4 5 on page 69 which are routed to DB 9 plug connections female P3 COM2 P22 COMB P23 COMB P24 COM or Phoenix plug or bare wire connections GC Controller TB J6 COM and J10 COMB Voltage Line drivers meet Electronics Industries Association EIA specifications for RS 422 Recommended Maximum Cable Length 4000 feet 1219 meters CPU and COMA Serial Communications Setups suty 2010 Installation and Setup 3 59 Model 500 Gas Chromatograph outs Terminal Board for Field Wiring at Controller FB 16 Terminal 2 Te Terminal 3 Terminal 5 Terminal 6 Terminal 7 3 Terminal Board for Field Wiring at Controller FB 110 COM Terminal 2 Terminal 3 Te Terminal 4 Terminal 5 Terminal 7 3 Terminal Board for Field Wiring at Controller FB Pa COM Terminal 2 5 1 Terminal
201. mode with EPROM RAM or FLASH installed effectively acts to disable the Solid State Disk and similarly when a DOC device is installed and the jumper is selected for standard devices the DOC is disabled Before using the M Systems the proper device type must be selected by correctly jumpering J11 The supported device type jumperings are shown here DOC DEVICE Figure 20 DisbOnChip Jumper Block JI1 uiv 2010 CPU and Serial Communications Setups 3 66 5 Installation and Setup Model 500 Gas Chromatagraph Multi l O Connector Parallel configuration jumper J2 Figure 3 21 Multi 1 0 Connector The VO to the serial channels the printer port and keyboard are all terminated via the connector at J1 A cable PIN 3 2350 089 plugs into the 50 pin connector CPU and COMAA Serial Communications Setups JULY 2010 Installation and Setup 3 87 Model 500 Gas Chromatograph Parallel Configuration Parallel configuration jumper J2 Figure 2 22 Parallel 1 0 Configuration The 16 bit CPU board LPM MCM 6117 uses the WinSyatemsit WS16C48 ASIC high density I O chip mapped at a base address of 120H The first 24 lines are capable of fully latched event sensing with sense polarity being software programmable Two 50 pin connectors allow for easy mating with industry standard UO
202. 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 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 Installation and Setup lt 37 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 UO lines in same conduit as A C power circuits see Figure 3 1 7 Use only shielded cable for digital T 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 SIGNALS TO AC POWER ALL OTHER AND FROM SIGNALS ANALYZER Figure 3 1 Seperate Conduit Entries uiv 2010 Signal Wiring 3 8 5 Installation and Setup Model 500 Gas Chromatagraph 8 When inductive loads relay coils are driven by digital output lines the inductive transients must be diode clamped directly at the 9 Any auxiliary equipment wired to the GC Controller must have its signal common isolated from earth
203. n be built for troubleshooting the GC System s analog input output operation See Figure 5 6 and Figure 5 7 t Figure 5 6 Analog Loopback with Two Analog Outputs uiv 2010 Analog Loopback Test Circuits lt 5 42 gt Maintenance Model 500 Gas Chromatagraph t p i poe um Figure 5 7 Analog Loopback with More Than Two Analog Outputs Analog Loopback Te JULY 2010 Maintenance 5 43 Model 500 Gas Chromatograph 5 8 7 Upgrading Analog Outputs As an option the GC Controller can be configured with additional analog outputs there are two analog outputs on the standard Analog Board PIN 50 041 For more analog outputs the existing Analog board must be exchanged for one of these optional Analog Boards allowing a quantity of either six or ten analog outputs see drawing BE 18044 in the GC Controller drawings addendum this manual Analog UO 6 analog outputs P N Analog LO 10 analog outputs PIN It additional analog outputs are installed the existing System Interface Driver board must be exchanged for one of these optional System Interface Boards allowing a quantity of either six or ten analog outputs see drawing CE 18118 Analog UO 6 analog outputs P N 3 2350 022 Analog UO 10 analog outputs PIN 3 2350 023
204. n remove the Card Cage away from its chassis mount so that it is easy to work on 7 Disconnect ribbon cable plugs from the cards in the Card Cage Assembly so that you insert and securely plug the 33 6 GC Internal Modem card into the COM4A Board 8 Plug the telephone line into the RJ 11 phone jack at the back edge of the GC Internal Modem card 9 Reconnect all ribbon cable plugs that were disconnected in step 8 above 10 Return and secure the Card Cage Assembly in its chassis mounting Tighten the four screws 11 Return and secure the GC Controller s Terminal Board for Field Wiring in its original position Hand tighten the six screws 12 Restore AC power to the 2350A GC Controller 14 Connect the telephone line from the GC Controller s Internal Modem to a wall phone jack if available or to the outside telephone system The above instructions can also be found in the MON2000 Software for Gas Chromato 2010 APPENDIX E SETTING SOLENOID PURGE FLOWS This appendix provides the stops needed to set up solenoid purge flow Solenoid purge flow is a necessary part of the normal operation of process GC systems that handle multiple streams and are equipped with optional solenoid purge system components solenoid purge system for the GC is available as an optional part of the GC sample conditioning system SCS The utility of a Solenoid purge system is greatest for GC systems with multiple St
205. nal 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 uiv 2010 Installation and Setup 3 17 Model 500 Gas Chromatograph Ifyou 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 PIN 9000522 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 eable must be
206. nance 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 serews Figure 28 COM ID DIP Such 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 uiv 2010 Modbus Slave Address COM ID Setup 334 Installation and Setup Model 500 Gas Chromatograph connected via COMS When the Board is installed If the COMAA Board is not installed the LOI is connected via Table 3 2 Modbus Slave Address COMID DIP Switch Settings Dip Switch Settings Switch Positions T 1 OFF OFF OFF OFF z OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF 5 OFF ON OFF OFF D OFF ON OFF OFF 7 ON OFF OFF D O
207. navailable for a serial PC connection Is the connection to be made in a 2 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 Is the connection to be made in a 2 on page 40 Hazardous or nonhazardous environment Short distance between the PC and Controller Permanent cable connection See PC to GC Permanent Cable Connection for Short Distance 232 on page 41 Is the connection to be made with a Long distance between the PC and Controller Permanent cable connection Seo 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 the shelf straight through serial cable connected to the GC Controller s front panel DB 9 serial port jack Controller PC Wiring Serial Connections JULY 2010 Installation and Setup 3 41 Model 500 Gas Chromatograph port jack proceed as follows SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Do not operate a PC in a including serial port are made through explosion proof conduit or flamoproof glands Failure to observe all safety precautions could result in serious injury or death 1 Obtain a straight through serial cable 0 feet long or less DB 9 or DB 25 female plug at one end for PC connection and
208. nd J10 This provides access to on J10 and on J11 of the Field Termination Board The serial port setup in the MON2000 Software for must be selected as PC port e For a system WITH a keyboard and display connect cable PIN 3 2350 087 from CPU J6 to the System Interface J8 and J12 This provides access to COMS on J10 and COMA is dedicated for use as a serial interface to the keyboard and display will not be available at J11 of the Field Termination Board The serial port setup in the MON2000 Software for must be selected as Front Panel See Figure 4 If all four serial ports are required for communications on a system with keyboard and display an optional COM4A Board must be installed and a COM and COMB cable P N 8 2350 086 connected see Section 4 0 below The serial port setup in the MON2000 Software for COMS must be configured as Front Panel See Figure 5 Reinstall the Analog cable to J6 on the System Interface Board g Place the Unit Updated to 2350A label included with the upgrade kit on the instruction decal located on the inside right wall of the explosion proof units or on the card cage of the rack or panel mount units Figure G 4 MON2000 Serial Port 8 Front Panel Configuration with COMAA Board Installed BASIC 2350A CONFIGURATION 2010 2350 to 2350A CPU Retrofit Instructions lt G 9 Model 500 Gas Chromatograph MON2000 5
209. nimum 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 Basic Analysis Computations Two basic analysis algorithms are included in the GC Controller These 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 Description 1 13 Model 500 Gas Chromatograph through calibration procedures with a calibration gas mixture that has known concentrations Response factor calculation using the external standard where ARE Asea response factor for component n in area per mole percent HRP Height response factor for component Area Aren associated with component nin calibration gas Hin Height associated with component n in mole percent in calibration gas Cal Amount af component n in mole percen
210. no leaks are present and the GC Controller is correctly timed Before going through the trou bleshooting procedures perform the routines of the Analyzer Maintenance Checklist Checklist records performed regularly may indicate problems and prevent any sudden breakdown Do not adjust any values if they are within the nominal tolerance values the Checklist Compare the values with those obtained in preceding weeks This may pinpoint your problem immediately The following is a guide for troubleshooting if a problem with sample analysis occurs Table 5 2 is a Troubleshooting Checklist to obtain data for a problem diagnosis This data will be useful if it becomes necessary to call the Daniel Measurement Services DMS a division of Emerson Process Management for assistance Flow Balance Check 1 Ensure that the flow panel gauge is reading properly Refer to the Analyzer Maintenance Checklist for values Do not adjust check with Daniel Measurement Services DMS a division of Emerson Process Management if your reading is abnormal 2 Check flow at the measure vent and sample vent see Troubleshooting Checklist Temperature Ensure that the temperature is constant in both the Analyzer and Sample Conditioning System SCS oven if an oven is used refer to Section 5 5 7 Temperature Measurements on page 25 Baseline Drift To ensure that the baseline is not drifting compare the baseline upsets caused by valv
211. o complete the remainder of all electrical connections at the GC Controller If so see Section 3 4 Installing the GC Controller on page 30 uiv 2010 Point to point Wiring Guide Analyzer Controller 324 Installation and Setup Model 500 Gas Chromatograph aw Jeo me men esia pieno tama qur Ej n wat eme Esa Connections at the Analyzer mne ree E J4 cone 2 794 4 E do rer cone 4 b ja enor cane 2 784 12 J ener cone 1 raan Connections at E the GC Controler Lr aw aura zeno Tair 1 HR ft Tag Figure 3 5 Analyzer and GC Controller Interconnect Leads Point to point Wiring Guide Analyzer Controller 2010 Installation and Setup 3 25 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 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 1f necessary complete wiring for connecting AC power to the Analyzer with proper connections to hot neutral
212. obe 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 88 tubing for connecting helium carrier to the analyzer 1 8 inch 88 tubing for connecting stream gas to the analyzer 7 Miscellaneous Swagelok tube fittings tubing benders and tubing cutter 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 switeh See previous guidelines in Section 3 1 2 Power Source Wiring on page 5 uiv 2010 Necessary Tools and Components 316 Installation and Setup Model 500 Gas Chromatagraph 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 Olea Proses and Warnings 2 Pina Site Location Obtain Supplies and Tools Install Analyzer Wiring Observe the following checklist of tools and components you may need for installing and using the GC System 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 exter
213. oller 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 Installation and Setup 3 39 Model 500 Gas Chromatograph What serial ports are available at the GC Controller When you select consider these points The GC Controller s COMI serial channel is usually reserved for connecting a PC especially for service or troubleshooting purposes since the GC Controller s easy nccess front panel serial port is connected to serial channel COMI x gt SERIAL PORT Figure 3 10 The Front Panel Serial Port is Connected to GC Controllers Serial Channel COMI COMB 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 COMB option must be RS 232 and is used for the display keypad Therefore there is no 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 uty 2010 Controller PC Wiring Serial Connections 3 40 gt gt Installation and Setup Model 500 Gas Chromatagraph 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 u
214. one of the Phoenix Plug serial ports of the GC and a PC with DB 9 serial port you will need to manufacture the cable and its DB 9 female plug cable end as illustrated below see Figure 5 w 8396 jor i t 8 cts T RIS 7 RIS CIS 6 DSR 5 GROUND 5 GROUND RD 2w 3 RID 1 RLSD DCD 1 RLSD DCD Female 9 plug for connecting Phoenix Plug to PC s serial port Figure 4 5 GC Phoenix Plug Port to PC DB 9 Port Phoenix Plug Port ot GC to DB 9 Port of PC JULY 2010 Supplemental Wiring Guide Serial Communications lt A 7 Model 500 Gas Chromatograph A 2 4 Phoenix Plug Port of GC to DB 25 Port of PC make an RS 232 serial connection between one of the Phoenix Plug serial ports of the GC and a PC with DB 25 serial port you will need to manufaetu below see Figure A 6 the cable and its DB 25 female plug cable end as illustrated 9R 8 CTS ARTS 7 RTS 5 CTS 6 DSR 5 GROUND 7 GROUND 4 DTR 3 RxD 200 21 3 RxD 1 RLSD DCD 8 RLSD DCD Female DB 25 plug for connecting Phoenix Plug to PC s serial port Figure A 6 GC Phoenix Plug Port to PC DB 25 Port uiv 2010 Phoenix Plug Port of GC to DB 25 Port of PC A B gt gt Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatagraph RS 232 CONNECTION FROM GC CONTROLLER TO
215. onnections Install Analyzer Wiring Install GC Controller Wiring x Istat Analyzer Sample amp Gas Lines B 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 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 uiv 2010 Controller PC Wiring Serial Connections 3 38 gt Installation and Setup Model 500 Gas Chromatagraph What serial ports are available at the PC When you select one consider these points Standard PC serial ports are type RS 2 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 089 08 25 PC serial ports can be designated as COMI through COMB 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 determine which PC serial ports are already being used by other equipment and which port can be used for connecting to the GC Contr
216. ow these steps 1 Halt any ongoing analyses Using the MON2000 Software program select the Control submenu from the Main Menu screen Then from the Control submenu press H to Halt MON2000 will ask you if uiv 2010 Detector Bridge Balance 5 24 gt gt Maint Model 500 Gas Chromatograph you want to Halt the Analysis Select Yes and press the ENTER key 2 Remove the cover of the upper explosion proof enclosure on the Analyzer 3 Refer to Figure 5 4 and attach the negative lead of a digital voltmeter to the black test point BRIDGE BALANCE Attach the positive lead of the digital voltmeter to the red test point BRIDGE BALANCE 4 Check the detector bridge voltage The voltage should read 0 millivolts mV 0 5mV Adjust the coarse and fine potentiometers immediately beneath the test points to obtain the specified reading Figure 5 4 Analyzer Detector Bridge Balance Locations Detector Bridge B ee suty 2010 Maintenance 5 25 Model 500 Gas Chromatograph 5 5 7 Temperature Measurements To measure the Detector and Heater Block temperatures you will need a Fluke Model 51 KIJ thermometer or equivalent measure Detector and Heater Block temperatures proceed as follows 1 Unserew the Condulet cover of the lower explosion proof XJT housing 2 Next loosen and remove the four two thumb screws that hold the Valve Driver board 3 Carefully edge the Valve Driver board off
217. perator panel casting rib This ground point should be connected to a copper ground rod as described next 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 Daniel Measurement Services 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 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 uiv 2010 Electrical and Signal Ground Model 500 Gas Chromatograph 3 1 5 Electrical Conduit 1 observe Precautions and Warnings 2 Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring
218. ph 5 7 COMMUNICATIONS See Section 3 4 4 this manual for a list of the GC Controller ports and terminale pins assigned to serial communications There are 3 to 8 communications ports available from the GC Controller In addition a communications port 8 is used by the GC Controller display and keypad The GC Controllerisplay link uses either RS 232C or RS 422 protocols Communications using RS 282C or RS 485 protocols are available in the additional external poris The communication protocols can be set with MON2000 if the GC is installed with an LX 800 CPU board the protocols can be set by changing jumpers if the GC is installed with a 6117 CPU board These jumpers are normally specified by the customer at the factory If it becomes necessary to change the communications at the sito access to the boards inside the enclosure is required to change the data interface chips The enclosure should not be opened when hazardous gases are present Refer to Section 5 6 1 GC Controller Access on page 29 if a communications change becomes necessary The Data Interface Chips to be changed are located on the 6117 CPU Board The standard configuration would be both channel 1 and 2 RS aac Optional chip configurations for the communications ports are Ib RS 232 1 large dip chip RS 485 1 small dip chip RS 422 2 small chips COMMUNICATIONS uiv 2010 Model 500 Gas Chromatograph Maintenance 5 31 5
219. placement temperature board is installed temperature set points must be re calibrated See Section 5 5 7 Temperature Measurements on page 25 Decoder Fuse Replacement The Decoder board is protected by a 3A 120VAC Picofuse which is installed in line on the neutral A C connection ta the board The fuse is located above the power strip in the lower right corner of the Decoder board and is replaced by unsoldering the bad fuse from the printed circuit board PCB and installing a new fuse Use a low power soldering iron Instructions for Removing the Decoder Board SERIOUS PERSONAL INJURY OR DEATH POSSIBLE The explosion proof housing should not be opened when the unit is exposed to an explosive environment If access to the explosion proof housing is required precautions must be taken to ensure that explosive environment is not present Failure to observe all safety precautions could result in serious injury or death 2010 Maintenance 4 5 11 Model 500 Gas Chromatograph To remove the Decoder Board from the upper explosion proof housing proceed as follows 1 Disconnect the Analyzer 120VAC power source 2 Loosen two screws securing the round Analyzer electronics faceplate and remove the faceplate 3 Pull the two printed circuit board assemblies out of the electronics housing Pull firmly making sure that the wiring harness does not catch on the top of either card Place e
220. pment 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 Daniel Measurement Services DMS a division of Emerson Process Management for further instructions Include complete model number information Disposition instructions will be returned immediately by Daniel Measurement Services Refer to the Customer Repair Report in the back of this manual Unpacking the Unit suty 2010 Installation and Setup 3 15 Model 500 Gas Chromatograph 3 2 4 Necessary Tools and Components 1 Observe Precautions and Warnings 2 Pian Site Location 3 Obtain Supplies and Tools Analyser Wiring 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 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 pr
221. quirements 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 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 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 regu
222. r most field wiring procedures without removing the enclosure 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 Loosen the six screws that secure the TB Then unplug the TB from its connections at the back top of the board Lower the TB down and out of the way held in place by its ground straps at the bottom of the board This exposes the Card Cage Assembly Loosen the four screws that secure the Card Cage Assembly to the chassis Then remove the Card Cage Assembly away from its chassis mount so that it is easy to work on Locate the System Interface and Driver board 1t is mounted to the top of the Card Cage Assembly Remove all cables connected to the System Interface Board PIN 3 2350 005 P N 3 2350 022 or PIN 3 2350 023 Remove the 1 048 board assembly drawing P N BE 12973 and cables from the top slot of the cage card assembly This board is not used on the 2350A GC Controller Remove the CPU Board assembly PIN CE 19281 and cables from the second slot of the card cage assembly This board is not used on the 2350A GC Controller Remove the DSPUO board assembly drawing P N CE 12976 and cables from the third slot of the card assembly This board is not used on the 2350A GC Controller 2010 C
223. r the front panel on its bottom hinges The front panel is heavy so make sure it does not drop and cause damage e For the rack mount Controller the rear of the enclosure is open it allows access for most field wiring procedures without removing the enclosure TO ADD A MODEM 2010 2350 10 2350A CPU Retrofit Instructions 6 13 Model 500 Gas Chromatograph 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 3 Loosen the six serews that secure the TB Then unplug the TB from its connections at the back top of the board 4 Lower the TB down and out of the way held in place by its ground straps at the bottom of the board This exposes the Card Cage Assembly Loosen the four screws that secure the Card Cage Assembly to the chassis Then remove the Card Cage Assembly away from its chassis mount so that it is easy to work on 6 Locate the System Interface and Driver board It is mounted to the top of the Card Cage Assembly a Disconnect the Analog cable from J6 of the System Interface Board then disconnect all CPU cables from the System Interface Board b Remove the CPU assembly and install the modem with associated hardware into J19 and J20 PC 104 Bus connector on the CPU casey If an option board is alread
224. reams in which the makeup of the different analysis streams may differ significantly from stream to stream For process GC systems with multiple streams a solenoid purge setup is necessary before starting normal GC operation solenoid purge check as outlined below is also recommended as part of a regular GC system maintenance schedule to be performed for example once every month The steps in this solenoid purge procedure ensure there is no cross stream contamination in multi stream sample systems Asa particular stream is being purged through the sample valve in the Analyzer that same stream is being purged through all the sample system solenoids This ensures that streams not being purged do not mix with the purging on hand the sample system drawing that system as part of the shipping package p o operate during this procedure e2 Setting Solenoid Purge Flows Model 500 Gas Chromatagraph To set up solenoid purge flow follow these steps 1 At the GC Controller halt continuous analysis At the Analyzer ensure that all streams to be analyzed are plumbed into the system and stream pressures are set to 15 20 psig 3 At the Analyzer locate and close the solenoid purge valve for each solenoid This is the valve plumbed to the normally open NO port of each stream solenoid Refer to the sample system drawing for the location of these valves 4 Access the Analyzer Valve Driver bo
225. rge gas and immediately all inlets and vents including the carrier drier These vents and inlets should be capped with the fittings that were in place when the GC shipped from the factory or with Swagelok caps not provided This will protect the columns and filters and should result in a trouble free start up when the unit is returned to service 12 Shipping and long term storage recommendations Model 500 Gas Chromatagraph The sample conditioning system vents and inlets should also be capped with the fittings that were in place when the system shipped from the factory Additionally all vents should be closed Any remaining openings such as conduit entries should also have appropriate plugs installed to prevent foreign material such as dust or water from entering the system 2010 ADDENDUM 1 ANALYZER DRAWINGS This addendum contains schematics and drawings of the Analyzer portion of the Model 500 Gas Chromatograph System Drawings are listed below in the same page order as found in this addendum CE 13004 DE 13081 CE 16120 CE 16180 CE 16220 CE 16278 CE 16320 CE 16420 BE 17204 DE 18300 DE 18301 CE 20234 CE 23858 CE 23878 Lower Assembly Model 512 Dual XJT w Power Supply Wiring Lower XJT Customer Interface Model 512 S C S Plate 1 Stream S C S Plate Single Stream with Model 101 Bypass S C S Plate 2 Streams S C S Plate 2 Streams with 101 Bypass S C S Plate
226. rminals 10 11 12 4 20 mA common shield Analogin 4 5 6 GC CONTROLLER MAINTENANCE The GC Controller is designed to operate for long periods of time without need for preventive or regularly scheduled maintenance If the Model 500 GC Controller is installed in an explosion proof enclosure it is dust water and flame proof SERIOUS PERSONAL INJURY OR DEATH POSSIBLE The explosion proof housing should not be opened when the unit is exposed to an explosive environment If access to the explosion proof housing is required precautions must be taken to ensure that an explosive environment is not present Failure to observe all safety precautions could result in serious injury or death Should there be need to open the explosion proof enclosure first disconnect all AC electrical power to the unit and ensure the area is free of explosive gases Also prior to opening the GC Controller check the operating parameters of the application with either a PC or the GC Controller s built in display and attempt to isolate or fix any incorrect parameters GC CONTROLLER MAINTENANCE 2010 Maintenance 5 29 Model 500 Gas Chromatograph 5 6 1 GC Controller Access access any of the GC Controller s electrical components perform all of the following steps if the Controller is in an explosion proof enclosure Step 2 is not applicable if the GC Controller is in a nonhazardous environment or Rack or Panel mount uni
227. romatograph should be secured to a wooden pallet maintained in a vertical position and enclosed in a wood framework with a cardboard skin Auxiliary equipment such as sample probes may be stored in the packaging in which it was shipped If this packaging material is no longer available secure the equipment to prevent excessive shaking and protect the accessories in a water proof enclosure The gas chromatograph should be stored in a sheltered environment that is temperature controlled between 30 C 22 F and 70 C 158 F to keep the gas chromatograph s protective coatings from deteriorating from exposure to rain or caustie or corrosive environments Humidity in the sheltered environment should be non condensing The program stored in the remote or integral controller memory may be retained through battery back up for at least two years If lost for some reason a custom program for downloading the appropriate GC application is included on the CD shipped with the system documentation Ifthe gas chromatograph has been in operation the system should be purged with carrier gas before powering the gas chromatograph down Allowing the gas chromatograph to perform a couple of analysis cycles without sample gas is an acceptable method of purging the system Monitor the results and remove power after component values fall to 70 or after peaks are significantly reduced in size After removing power from the GC remove the pu
228. rts depending on options The serial signal definitions and the ports that support them are as follows PCI CPU RS sans J5 J6 J10 and JI1 35 J6 J10 and J11 35 36 J10 and J11 and DE 9 ports P2 and P3 and DB 9 ports P2 and P3 and DB 9 ports P2 and P3 COM4A m msc Com P22 Com 6 P23 Com 7 P24 The serial ports and terminals listed above are located on the GC Controller s Terminal Board for Field Wiring uiv 2010 CPU and COMAA Serial Communications Setups 346 gt Installation and Setup Model 500 Gas Chromatagraph Serial ports configured for RS 232 are most commonly used for direct serial communication between the Controller and a PC or a modem The front panel serial port on the GC Controller is configured for RS 232 by default and is connected to the Controller s serial port CONI Consequently the Controller s COM is usually reserved for direct serial communication between the Controller and a PC telephone Modem Board plugs into the COMAA Board and can be Configured for RS 232 For directions on how to connect a modem to the GC Controller see Appendix G 4 and the MON2000 Software for Gas Chromatographs User Manual P N 3 9000 522 Serial ports configured for RS 422 or RS 485 are most commonly used for long distance serial communications systems such as a Data Collection System or a multi drop serial data highway net
229. run inside conduit for hazardous environments For cable termination details see Section 3 3 1 this manual 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 Gee Section 3 4 3 3 for directions on how to install this cable 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 uiv 2010 Optional Tools and Components 318 gt Installation and Setup Model 500 Gas Chromatagraph 3 3 INSTALLING THE ANALYZER 3 3 1 Point to point Wiring Guide Analyze Controlle beer Prats and 1 Warnings Plan Site Location Obtain Supplies and Tools stall Analyser Wiring This section applies only to GC systems which have not been shipped prewired In most cases the explosion proof system wil already have had the Analyzer Controller connections made If your system has already been wired
230. s In addition the Unified Baseline Operating System UniBOS is now resident on a 128 MB CompactFlash card instead of the slower 16 MB DiskOnChip module The CompaetFlash card provides additional memory for archiving data The UniBOS file on the CompactFlash card can be upgraded in the field with MON2000 Refer to the MON2000 Software for Gas Chromatographs user manual which is located on the MON2000 CD ROM for information about downloading 2350A applications and UniBOS upgrades introduction 2010 6117 CPU to LX 800 CPU Upgrade Instructions lt H 3 Model 500 Gas Chromatograph JS is preloaded on the LX 800 CPU board Do not to install BOS or an earlier version of UniBOS Doing irreversibly corrupt the firmware and will require the purchase of new CPU board To leam tho version leve he UniBOS loaded onto your CPU board of o the label on Other relevant facts about the LX 800 CPU board include Optional boards can be plugged directly into the PC104 bus 64 pin connector J29 and 40 pin connector J27 on the CPU board assembly An optional board provides four additional serial ports through modem card be plugged directly into the PC104 bus for additional communications capabilities If you plan to install a CSA approved Radicom modem and two or more PC104 boards the modem must be installed on top of the PC104 stack because the modem has only one PC
231. s Recommended Maximum Cable Length 50 feet 15 meters Pinouts Peery Terminal Hoard for Field Wiring at Controller TE COMI Terminal 1 RISD DD 16 Ta COM3 or Terminal 2 sour ICOM Terminala Six RxD Terminal d Terminal 5 GND Terminal DER Terminal 7 Terminal 5 Terminal 9 E CPU and COMA Serial Communications Setups suty 2010 Installation and Setup 3 57 Model 500 Gas Chromatograph Terminal Board for Field Wiring at Controller TB P22 COMS Terminal 1 NC P23 COMB I COMA Terminal 2 Sour xD Terminal 3 x iD Terminal 4 DSE Terminal 5 GND Terminal 6 DIR Terminal T Terminal 8 Terminal 9 RI Terminal Board for Field Wiring at Controller TB P2 COMD or Terminal 1 RISD DOD P3 COMB Terminal 2 Sour a Terminal Terminal 4 DIR e Terminal 5 IND seet Terminal 6 DSR NOTE DES Terminal RIS plug on GC Con troller is wired Terminal 5 to eliminate the Terminal RI need for a null modem cable between the GC and a PC uiv 2010 CPU and COMA Serial Communications Setups 3 58 gt Installation and Setup Model 500 Gas Chromatagraph mss Terminal Hoard for Field Wiring at Controller TH P22 COM Ter
232. s could result in serious injury or death 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 For the rack mount Controller the rear of the enclosure is open it allows access for most field wiring procedures without removing the enclosure Locate the GC Controller s Terminal Board for Field Wiring TB The TB is attached to the GC Controller s eard cage assembly facing the enclosure s front panel In the rack mount Controller the TB faces outward toward the rear of the enclosure Loosen the six screws that secure the TB Then unplug the TB from its connections at the back top of the board 4 Lower the TB down and out of the way held in place by its ground straps at the bottom of the board This exposes the Card Cage Assembly uiv 2010 TO ADD AN ETHERNET CARD 6 16 gt 2350 to 2350A CPU Retrofit Instructions Model 500 Gas Chromatagraph 5 Loosen the four screws that secure the Card Cage Assembly to the chassis Then remove the Card Cage Assembly away from its chassis mount so that it is easy to work on 6 Locate the System Interface and Driver board It is mounted to the top of the Card Cage Assembly a Disconnect the Analog cable from J6 of the System Interface Board then disconnect all CPU eables
233. s required precautions mus an explosive environment is not present Failure to observe all safety precautions could result in serious injury or death To replace the Decoder Board proceed as follows 1 Pull the power and interconnect cables out of the front center of the housing 2 Insert the board into the housing Push the end with short guides into the top rear and hold the interconnect cable down while the board is maneuvered into the housing 3 Push the top cable into the top of the housing Then position the board soit can be held in place by its four captive serews at the board s four 4 Tighten the four eaptive screws to secure the board in place 5 Attach the wires and plugs that were disconnected while removing the Decoder board 6 Mount the two nylon spacers on the mounting studs near the center top and bottom of the Decoder board 7 Reinstall the two printed circuit boards such that the component sides of the boards face outward left and right see Figure 5 1 The temperature controllerivalve drive board is in the left slot and the preamp is in the right slot 8 Replace the housing faceplate making sure that the switch shoulders are inside the locating holes Decoder 2010 Maintenance 5 13 Model 500 Gas Chromatograph 5 5 4 Analyzer Troubleshooting Guide process gas chromatograph can operate properly only if flows are balanced and constant the temperature is constant
234. se items Communication ports COM1 COM2 COM3 COM5 COME COM7 and COMBS uiv 2010 Controller Hardwar Configurations 2 22 Equipment description Model 500 Gas Chromatagraph Digital inputs and outputs Controller Analyzer interconnections Parallel printer port and Optional stream switching assemblies drawing DE 20782 for an llustration of the GC Control 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 ion analog output and stream switching options The System Interface and Driver board provides these functions Drivers for switching the eight optional valve solenoi Location for 8 position DIP switch to set the Modbus addres Opto isolation circuits for the diserete inputs and outputs Switching power supply and temperature shutdown circuit for the LCD display RS 282 to RS conversion for the LCD display and Voltage to current conversion for the analog outputs Controller Hardware Configurations uiv 2010 Equipment description 2 23 Model 500 Gas Chromatograph Jumper for selecting driving voltage
235. sumes the risk of loss of the product during shipment 3 To obtain warranty service or to locate the nearest DMS office sales office or service center do one of the following Call 713 827 6380 Fax a request to 713 827 6312 Write to Daniel Measurement Services 11100 Brittmore Park Drive Houston Texas 77041 Contact DMS via www emersonprocess com daniel 4 When contacting DMS for product service the Purchaser is asked to provide information as indicated on the following page entitled Customer Repair Report For product returns from locations outside the United States it will be necessary for you to obtain the import consignment address so that DMS s customs broker can handle the importation with the U S Customs Service 6 DMS offers both on call and contract maintenance service designed to afford single source responsibility for all its products 7 DMS reserves the right to make changes at any time to any product to improve its design and to insure the best available product This page is intentionally let blank CUSTOMER REPAIR REPORT FOR SERVICE COMPLETE THIS FORM AND RETURN IT ALONG WITH THE AFFECTED EQUIPMENT CUSTOMER SERVICE AT THE ADDRESS INDICATED BELOW COMPANY NAME TECHNICAL CONTACT PHONE REPAIR P IF WARRANTY UNIT SIN INVOICE ADDRESS SHIPPING ADDRESS RETURN SHIPPING METHOD EQUIPMENT MODEL sin FAILURE DATE DESCRIPTI
236. t in calibration gas 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 REAVG ii 2010 Computations 1 14 Description Model 500 Gas Chromatograph where REAVG Area or height average response factor for component n E Area height response factor for component n from the calibra D Number of calibration runs actually used to caleulate the response factors The percent deviation of new RF averages from old RF average is calculated in the following manner 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 where CONC Concentration of component n in mole percent Area Area of component n in unknown sample Basic Analysis Computations JULY 2010 Description 1 18 Model 500 Gas Chromatograph ARE Response factor of component n calculated from area of calibration sample Units are area por mole percent Hig Peak height of component n in unknown sample HRF Response factor of component n calculated from peak height of cal
237. technical 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 GC Controller Circuit Board List The GC Controller circuit boards are inserted or attached to an STD bus card assembly The Controller has two boards inserted into the card 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 COMAA serial ports 5 6 7 and 8 Ethernet uiv 2010 Controller Hardware Configurations 220 Equipment description Model 500 Gas Chromatagraph There are two optional piggy back boards that can be attached to the LX 800 CPU board via the PC 104 bus Modem COMAA 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 Ethernet board must be used onboard ethernet port Controller Hardware Configurations uiv 2010 Model 500 Gas Chromatograp
238. ten analog outputs sae drawing BE 18044 in the GC Controll drawings addendum this manual lt Analog VO 6 analog outputs P N 3 2360 039 Analog lO 10 analog outputs PIN 3 2350 034 additional analog outputs are installed the existing System Interface Driver board must be exchanged for one of these optional System Interface Boards allowing a quantity of either six or ten analog outputs see drawing CE 18118 lt Analog lO 6 analog outputs P N 3 2350 022 Analog lO 10 analog outputs PIN 3 2350 023 I additional analog outputs are installed specific transient protection modulos must also be installed on the GC Controller s Terminal Board for Field Wiring TB For details about transient protection modules see Appendix C Also see drawing CE 18115 sheet 2 in the GC Controller drawings addendum this manual Once the Analog Board System Interface Board and the pro transient protection modules are installed field wiring for the added analog outputs from the GC Controller are made to GC Controller TB ports 13 and J15 Analog UO Wiring suy 2010 Installation and Setup 3 77 Model 500 Gas Chromatograph 3 4 8 Controller AC Power Wiring Analyzer Wiring 5 Install Analyzer Sample amp Gas Lines Ina GC Controller Wiring T Perform Leak Checks connect 115 or 130 volts AC Power to the GC Controller follow these steps
239. tenance 5 23 Model 500 Gas Chromatograph Management The following are procedures for overhauling the valve using a Rebuild Kit from Daniel Measurement Services DMS A torque wrench sealed in foot pounds is required Valve Overhaul Instructions To overhaul the Chromatograph valve follow these steps and refer to drawing CE 20234 in the Analyzer drawings addendum of this manual 1 Remove the malfunctioning valve from the Analyzer Secure the valve in vise clamping only at the baseplate 2 Loosen the torque bolt by turning counterclockwise 3 Remove the entire valve from the vise and prepare for disassembly in a clean area 4 Remove the torque bolt and disassemble the valve starting with the primary plate Carefully slide the remaining portion of the valve from the mounting fixture 6 Inspect each valve piece for obvious debris scratches or contamination and clean as required with sonic cleaner or electrical contact cleaner DO NOT USE AN OIL BASE CLEANER After cleaning blow clean dey instrument air or Helium through the valve ports 7 Discard the old valve diaphragms Replace the old valve diaphragms with the new diaphragms in the valve repair kit 8 Re assemble the valve by following the instructions in drawing CE 20234 5 5 6 De tector Bridge Balance The following procedure should be carried out if the Analyzer does not produce a chromatogram To perform a detector bridge balance foll
240. terface Board Fuse Size and Capacity Slo Blo 2 5 amperes 250 VDC ANALYZER CONTROLLER INTERCONNECT Signals between the Analyzer and GC Controller are conducted on the Analyzer Controller Interconnect Cable Excluding signal common these signals are as follows see also Section 3 3 and Table 3 2 Four outputs from the Analyzer preamplifier 4 20 mA current loop These are the amplified electrical output from the Analyzer detector and bridge Function Code signals the Function Code Strobe and Auto Zero These signals are initialized at the GC Controller and interpreted at the Analyzer decoder board in order to properly time a the Analyzer and stream valve activations and b zeroing of the Analyzer pre amp signals output Alarm function Seo Figure 5 10 next page for a schematic that identifies the Analyzer Controller Interconnect Cable terminations ANALYZER CONTROLLER INTERCONNECT uiv 2010 Maintenance 547 Model 00 Gas Chromatograph P Deme LEE DRM d pem Ens eme B HN r Correctons at the ons ELM T ees at hagas the GC Conirder raa Figure 6 10 Analyser and GC Controller Interconnect Leads 2010 ANALYZER CONTROLLER INTERCONNECT lt 5 48 5 Maintenance Model 500 Gas Chromatagraph 5 11 1 Function Codes If the Analyzer
241. 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 Figure G 2 Explosion Proof Controller DIP Switch uiv 2010 CONVERSION PROCESS G 6 gt 2350 to 2350A CPU Retrofit Instructions Model 500 Gas Chromatograph 17 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 Figure G Right Side View of Rack Mount and Panel Mount Controllers 18 Ingpect or change the DIP switch settings as necessary a See Table G 1 as a guide b Make sure you record in the GC Controller s maintenance records any changes you make to the switch settings 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 is the most significant bit Switch to ON 1 Switch to OFF Switch 6 is a spare for future use Switches and 8 are set needed for the presence of an optional LOI Local Operator Interface connected via When the COM4A Board is installed If the COMAA Board is not installed the LOL is connected via CONVERSION PROCESS uiv 2010 2350 to 2350A C
242. thus reduce the effective incoming data rate to 40 N samplesisecond 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 i where PW is given in seconds AIL 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 forma 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 Description 1 11 Model 500 Gas Chromatograph 153 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 Peak Detection For normal area or peak height concentration evaluation the determin
243. ticipated 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 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 electronies and ports for signal processing instrument control data storage personal computer PO interface and telecommunieations 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 1 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 2010 Description 1 3 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
244. to slot 5 of the card cage 2 Locate the analog cable P N 8 2350 077 Rev D that is supplied with the analog board Plug the end of the cable that is labeled ANLG J6 into the header labeled J6 on the analog board 3 Plug the end of the cable that is labeled INTF J6 into the system interface board header labeled J6 4 If applicable install the second analog cable PIN 3 2350 076 Plug the end of the cable labeled ANLG 45 into the header J5 on the analog board Plug the other end of the analog cable labeled INTF J5 into the header labeled J5 on the system interface board Press down firmly on both the analog board and the CPU board to insure they are completely seated into the connectors on the backplane REASSEMBLING THE 2350A To reassemble the 2350A do the following 1 Reinstall the card cage in the rack mount or explosion proof housing by screwing in the card cage s thumb screws 2 Ifa COM4A board is installed mount the DB9 connectors for serial ports COMS P22 COMG P23 and COM P24 into their designated slots at the top right side of the field termination board uiv 2010 Installing a New Analog Board HM 3 6117 CPU to LX 800 CPU Upgrade Instructions Model 500 Gas Chromatograph This page is intentionally left blank Reassembling the 2350A uty 2010 APPENDIX SHIPPING AND LONG TERM STORAGE RECOMMENDATIONS The following recommendations should be followed For shipping purposes the gas ch
245. tput 8 Low Same as number 19 Analog Output 9 Low Same aa number 19 Analog Output 10 Low Same as number 19 29 Analyzer Failure Carrier gas low below 105 PSIG at Carrier Gas bottle or gone bad solenoid carrier gas leak in 30 Power Failure The GC Controller has experienced a re start since alarms were last cleared caused by power failure Automatically starts in RUN mode and runs Cal gas until it identifies all retention times or a maximum of two hours before switching to line gas 31 Fused Peak Overflow Noisy Baseline Air not purged from carrier lines bad thermistors preamp out of balance o failed 32 RE Deviation Calibration gas low or out valve timing error faulty auto calibration solenoid Warm Start Calibration faila Same as number 32 suty 2010 SERVICE TROUBLESHOOTING AND REPAIR INSTRUCTIONS s10 Maintenance Model 500 Gas Chromatagraph 554 552 553 Preamplifier The preamplifier has no parts that may be serviced in the field Ifthe unit fails return it to Daniel Measurement Services DMS a division of Emerson Process Management for repair or replacement Temperature Control The temperature control circuitry is not field serviceable If the board fails return the board to Daniel Measurement Services DMS a division of Emerson Process Management for repair or replacement Ifa re
246. ts 1 Ensure AC electrical power is disconnected from the unit and the environment is safe 2 Remove the 16 screws holding the front panel with the display to the enclosure The front panel has hinges at the bottom secured by a cotter pin and the panel will fold down This front panel is heavy so make sure it doesn t drop and cause damage 3 Inside is the card cage holding the circuit boards The termination board is held to the card cage by six serews and is plugged into the System Interface Board near the top edge Loosen the screws and pull the termination board out as far as the wires will allow Let it lie flat inside the enclosure Remove the AC power connector from tho front of the termination board on the lower left hand side 4 With a flat bladed screwdriver at least 8 long remove two screws at the lower front corners and two screws at the upper rear corners of the card cage Carefully lift the card eage up and out until access is gained to the circuit boards Note the location of any board removed Remove only one end of any cable necessary to obtain access to the desired board Remember or make note of the eable installation so the eables can be replaced in the same order Release the catch es and removelreplace the circuit board s as necessary 6 Replace the card cage and tighten screws in the reverse order as the disassembly uiv 2010 GC Controller Access 5 30 gt Maintenance Model 500 Gas Chromatagra
247. ugh the line to the Analyzer until all gauges read 0 psig 11 Repeat steps 8 and 9 two more times to purge line to Analyzer 12 Close V 3 leave V 2 open 13 Open cylinder valve of Carrier Cylinder 1 and with carrier gas flowing at 10 psig or below connect carrier line to Analyzer 14 Slowly regulate Carrier Cylinder 1 to 110 psig 15 Open V 3 and slowly regulate Carrier Cylinder 2 to 100 psig doing this all but 100 pounds of Carrier Cylinder 1 will be used before any of Carrier Cylinder 2 is used When Carrier Cylinder 1 gets to 100 pounds refill the cylinder Leak check all of the fittings carefully 16 Lot Analyzer run overnight before calibrating 2010 INSTALLATION AND LINE PURGING Manifold for Two Carrier Gas Bottles to GC System Model 500 Gas Chromatograph REPLACING CARRIER CYLINDER replace one carrier evlinder without interrupting GC operation proceed as follows 1 Turn cylinder valve off 2 Back off on eylinder pressure regulator until handle turns freely Remove cylinder 3 Attach new cylinder to regulator and repeat steps 3 through 6 of Installation Instructions using appropriate bleed valve to purge line Leak check the fitting 4 Open block valve to Analyzer V 2 or V 3 and regulate outlet pressure to appropriate level See steps 14 and 15 of Installation Instructions REPLACING CARRIER CYLINDER 2010 APPENDIX GUIDE TO TRANSIENT P
248. ustrated but for reference purposes only i MALE DB FEMALE pin number socket numbering pinout for both DB 9 female jacks at GC Controller 5 4 2 1 GND ost RxD 9 7 6 Figure A 2 DB 9 Connector P2 P3 P22 P23 and P24 and Pinout for Female Jacks uiv 2010 GC SERIAL PORT AND CABLE CONFIGURATIONS FOR RS 232 A4 gt Supplemental Wiring Guide Serial Communications Model 500 Gas Chromatograph A2 RS 232 CONNECTION FROM GC CONTROLLER TO PC A 2 1 DB 9 Serial Port of GC to DB 9 Port of PC To make an RS 232 serial connection between one of the DB 9 serial ports of the GC and a PC with DB 9 serial port you may be able to use straight through serial cable terminated as DB 9 male DB 9 female This will work if the PC has a male DB 9 serial port and its pin assignments are identical to those found on a typical DB 9 serial port of an IBM PC The necessary straight through serial cable can be obtained from most computer products suppliers so custom building a cable normally is not necessary Wiring and signal path are illustrated as follows see Figure A 3 5 aed 4 5 A v m gt z oR 8 RIS acts 7 OTS TRIS 6 DTR 6 DSR 5 GROUND 5 GROUND 4 DSR 4 DTR 3 RxD 2 TD 2RD 1 RLSD DCD 1 RLSD DCD Female DB 9 plug for connectin karaa 10 POS por S Figure A 3 GC DB 9 Port to PC
249. valves are not being activated during Continuous Operation or Auto Sequence mode it may be necessary to determine whether Function Code signals are being transmitted correctly This section provides a guide to the Function Codes The four Function Code signals form a binary number which after interpretation by the Analyzer s decoder board determines the position of specifie chromatograph valves Chromatograph valve positions are either SET ON or RESET OFF Table 5 6 lists the voltage measurements that should occur at the Function Code terminals for corresponding states of the chromatograph valves A measurement of 5 five volts at any of the function code terminals indicates a binary zero 0 A measurement of 0 zero volts indicates a binary one 1 For additional reference Table 5 7 provides the Funetion Code dictionary hexadecimal for corresponding states of the chromatograph valves Function Codes 2010 Model 500 Gas Chromatograph Maintenance 5 49 Table 5 6 Voltage Meagurementa at Function Code Terminals Function Code Fonction Code Function Code Function Code TB Terminal No 418 1 ES duos Tu Analyzer Terminal No TBi 11 TBA 12 TBA VOLTAGE MEASUREMENTS Valve 1 ON volta DO ssepe avos DC Valve 1 OFF 0 5 a 5 Valve ZON 5 0 a Valve 2 OFF D D a Valves ON D 5 a 0 Valves OFF 5 0 a D Valve 10N
250. vices Products purchased by Seller from a third party for resale to Buyer Resale Producta 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 0 8 point of manufacture that portion of the Goods or firmware found by Seller to be defective or refund tha purchase price of the detective portion of the Goods Sarvices All replacements or repairs necessitated by inadequate maintenance normal wear and usage unsuitable power sources unsuitable environmental Conditions accident misuse improper instalation 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 sentative 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
251. witches upper XJT box are set to the AUTO position b Unplug or open the MV and SV vent lines c If the calibration gas bottle was used to leak check the sample stream lines reconnect the calibration gas bottle to the calibration gas line on the SCS mounting plate and reconnect the sample stream lines Plugged Lines Columns or Valves To ensure that lines columns and valves are not plugged check the gas flow at valve ports For a reference use the flow diagram in the drawing package and remember these points about flow diagrams Port to port flow paths are indicated by solid or dashed lines A dashed line indicates flow direction when the valve is ON that is energized solid line indicates flow direction when the valve is OFF that is de energize combination of solid and dashed lines indicates a constant flow path regardless of the ON OFF state of the valve Chromatograph Valves Valve Cleaning A sonic cleaner is ideal for valve cleaning However for field service purposes electrical contact cleaner also works well DO NOT USE AN OIL BASE CLEANER Valve Ovi The chromatograph valve is designed to withstand millions of actuation cycles without leakage or failure If service is required the valve ean be overhauled using a standard kit of replacement parts available from Daniel Measurement Services DMS a division of Emerson Process Chromatograph Valves JULY 2010 Main
252. work For these systems the GC Controller can communicate a Modbus slave device In any Modbus host slave DCS or multi drop serial data highway network there must only be one host to which any one of the GC Control jal ports can respond as a Modbus slave With four serial ports the GC Controller could be connected to a maximum of four different serial data networks For more details about using the MON2000 Software to configure the GC Controller for Modbus communication and determining contents of the Controller s Modbus registers see the MON2000 Software for Gas Chromatographs User Manual PIN 3 8000 522 CPU and COMA Serial Communications Setups JULY 2010 Installation and Setup 3 47 Model 500 Gas Chromatograph To connect serial communi follow these steps ions lines to the GC Controller 1 Access the GC Controller s Terminal Board for Field Wiring TB If necessary see instructions in Section 3 4 1 COM ID Setup on page 30 lodbus Slave Address 2 Route serial communications lines appropriately especially in the of the explosion proof Controller enclosure SIGNALS To AC POWER ALL OTHER AND FROM SIGNALS ANALYZER Figure 3 11 Seperate Conduit Entries 3 Make serial communications line connections to the GC Controller The port numbers and pinouts are listed in the following serial specifications sections uiv 2010 CPU and Serial
253. y 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 em 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 uiv 2010 Site Selection 14 gt Installation and Setup Model 500 Gas Chromatagraph 3 2 3 Unpacking the Unit 1 Observe Precautions and Warnings 2 Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring Observe the following checklist for unpacking the unit and inspecting for damage 1 Unpack the equipment a Model 500 series Analyzer GC Controller 2 Ensure that all documentation and software are included a This manual the Model 500 Gas Chromatographs Hardware Reference Manual PIN 3 9000 537 b The software manual MON2000 Software for Gas Chromatographs User Manual PIN 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 shi
254. y into the PC 104 Bus for additional communications requirements The PC 104 Bus is designed to allow any combination of option boards to be installed in any order refer to Figure 1 NOTICE If you are using the CSA approved Radicom modem er is the top card in the card cage assembly The connection configuration of the Radicom modem requires installation at the top of the assembly re that it G2 5 2350 to 2350A CPU Retrofit Instructions Model 500 Gas Chromatagraph Figure 1 CPU PC 104 Bus with COMAA Board G 2 CONVERSION PROCESS 1 At the GC Controller site remove the Controller enclosure s front panel 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 CONVERSION PROCESS uiv 2010 Model 500 Gas Chromatograph 10 2350 to 2350A CPU Retrofit Instructions lt G 3 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 For the rack mount Controller the rear of the enclosure is open it allows access fo
255. y plugged into the PC 104 bus on the CPU the modem and mounting hardware wil be installed into the PC 104 connector on the option board uiv 2010 TO ADD A MODEM G 14 gt 2350 to 2350A CPU Retrofit Instructions Model 500 Gas Chromatagraph Figure G 8 Modem c Plug one end of the modem extension cable P N 3 2350 075 into 21 of the modem assembly The in line jack on the remaining end of the modem extension cable attaches to the lower left inside wall of the card cage shield after the CPU assembly is reinstalled and all cables reconnected to the System Interface Board No software setup is required for this board 7 use an existing Modem 1414 a For operation with the 2350A CPU sot the Standard 1414 Modem jumpers per the following table Table G Jumpers Jumper Pin dus d TO ADD A MODEM 2010 2350 to 2350A CPU Retrofit Instructions lt G 15 Model 500 Gas Chromatograph b On the 2350A WinSystems CPU set J21 pin 13 14 G 6 TO ADD AN ETHERNET CARD 1 At the GC Controller site remove the Controller enclosure s front panel SERIOUS PERSONAL INJURY OR DEATH POSSIBLE 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 precaution

Model 500 Gas Chromatograph Hardware Reference Manual

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