MODEL 51 OOA CO ANALYZER - Emerson Electric · After installation or troubleshooting, all...

MODEL 51 OOAC O A N A L Y Z E R

Instruction Bulletin IB-106510A Rev. 2.1

ROSEMOUNT”ANALYTICA1FISHEfkRBSEMOUNT”Managing The Process Better:

HIGHLIGHTS OF CHANGES

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2-12

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9-4

Effective November, 1997 Rev. 2.0

SUMMARY

Added RS-232 information to control module description in paragraph 1.2.

Added RS-232 information to performance specifications in paragraph l-4.

Added RS-232 interface option to Figure 2-12.

Added RS-232 information to paragraph 2-&b.(g).

Added RS-232 information to control module description in paragraph 3-2.d

Added RS-232 interface option to Figure 3-7.

Added RS-232 information to paragraph 6-6~1.

Added rear interface PC board callout to Figure 8.35.

Added RS-232 I&U interface control module to Table 9-2. Updated solenoid/dual gas assembly part number in Table 9.2.

Added slider port and chopper motor w/solenoid/dual gas cell assembly in Table 9.4. Updated existing chopper motor and solenoid dual/gas cell part numbers in Table 9.4.

Added RS-232 rear interface control module to Table 9-S Updated existing rear interface control module in Table 9-5.

10-l Changed the European address.

I-3 Added RS-232 to index.

PAGE SUMMARY

Effective November, 1998 Rev. 2.1

3-13 Added step (a)(3) to Audible Alarm paragraph 3-3x.3.

3-43 Changed terminal numbers in paragraphs 3.g.c.l.(c) and 3-8x.4.(c).

ROSEMOUNT WARRANTY

Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount shall, upon prompt written notice from the purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts. Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount with respect to the quality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR PURPOSE).

The remedy(ies) provided above shall be purchaser’s sole remedy(&) for any failure of Rosemount to comply with the warranty provisions, whether claims by the purchaser are based in contract or in tort (including negligence).

Rosemount does not warrant equipment against deterioration due to environment. Factors such as corrosive gases and solid particulates can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the warranty period.

Equipment supplied by Rosemount Analytical Inc., but not manufactured by it, will be subject to the same warranty as is extended to Rosemount by the original manufacturer.

At the time of installation it is important that the required services are supplied to the system and that the electronic controller is set up at least to the point where it is controlling the sensor heater. This will ensure, that should there be a delay between installation and full commissioning that the sensor being supplied with ac power and reference air will not be subjected to component deterioration.

PURPOSE

The purpose of this manual is to provide a comprehensive understanding of the Model 5100A CO Analyzer, components, functions, installation, and maintenance.

This manual is designed to provide information about the Model 5lOOA CO Analyzer. We recommend that you thoroughly familiarize yourself with the Overview and Installation sections before installing your analyzer.

‘Ike overview presents the basic principles of the Model 5loOA CO Analyzer along with its performance characteristics and components. The remaining sections contain detailed procedures and information necessary for installation and servicing of the Model 5100A CO Analyzer.

Before contacting Rosemount concerning any questions, first consult this manual. It describes most situations encountered in your equipment’s operation and details necessary action.

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.

NOTE

Highlights an essential operating procedure, condition, or statement.

NOTE TO USERS

The number in the lower right comer of each illustration in this publication is a manual illustration number. It is not a part number and is not related to the illustration in any technical manner.

IB-106.510A

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IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS

The following safety ioslxoctions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or National Standards.

1. Adequate earth connections should be made to all earthing points, internal and external, where provided,

2. After installation or troubleshooting, all safety,covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC2.45

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C

5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.

7. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment - and then only by trained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer to the Operator Manual for instructions.

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10. All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and IS03864.

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BELANGRIJK

Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel.

De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lid&ten. Hier moet aan gebouden worden om de onderworpenheid aan de Laag Spannings Ricbtlijn (Low Voltage Directive) te verzekeren. Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften.

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Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten, intern en extem.

Na install& of controle moeten alle veiligheidsdeksels en -aardingen temg geplaatst worden. Ten alle tijde moet de betrouwbaarheid van de aarding behouden blijven.

Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC245 voorschriften.

Alle bekabeling meet geschikt zijn voor het gebroik in omgevingstemperatoren, hoger dan 75°C.

Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd is.

Om de veilige werking van dit to&e1 te verzekeren, meet de voeding door een stroomonderbreker gevoerd worden (min 10A) w&e & draden van de voeding meet onderbreken. De stroomonderbreker mag een mechanische schakelaar bevatten. Zoniet meet een andere mogelijkheid bestaan om de voedingsspanning van het toestel te halen en ook duidelijk zo zijn aangegeven. Stroomonderbrekers of schakelaars moeten onderworpen zijn aan een erkende standaard zoals IEC947.

Waar toestellen of deksels aangegeven staan met het symbool is er meestal hoogspanning aanwezig. Deze deksels mogen e&l verwijderd worden nadat de voedingsspanning werd afgelegd en enkel door getraind onderhoudspersoneel.

Wax toestellen of deksels aangegeven staan met het symbool is er gevaar voor hete oppervlakken. Deze deksels mogen enkel verwijderd worden door getraind onderhoudspersoneel nadat de voedingsspanning verwijderd werd. Sommige oppper- vlakken konnen 45 minuten later nog steeds heet aanvoelen.

Waar toestellen of deksels aangegeven staan met het symbool gel&e het handboek te raadplegen.

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10. Alle grafische symbolen gebruikt in dit produkt, zijn atkomstig uit een of meer van devolgende standaards; EN61010-1, IEC417 en ISO3864.

VIGTIGT

Sikkerhedsinstruktion for tilslutning og installering af dette udstyr.

F0lgende sikkerhedsinstruktioner gaelder specifikt i alle EU-medlemslande. Instruktionernc skal n0je f0lges for overholdelse af Lavsspaendingsdirektivet og h0r ogsH f0lges i ikke EU-lande medmindre andet er specificeret af lokale eller nationale standarder.

1. Passende jordforbindelser skal tilsluttes alle jordklemmer, inteme og eksteme, hvor disse forefindes.

2. Efter installation eller fejlfinding skal alle sikkerhedsdreksler og jordforbindelser reetableres.

3. Forsyningskabler skal opfylde krav specificeret i IEC227 eller IEC245.

4. Alle ledningstilslutninger skal vaxe konstmeret til omgivelsestemperatar h@jere end 75” C.

5. Alle benyttede kabelforskmninger skal have en~intem dimension, si passende kabelafIastning kan etableres.

6. For opnMse af sikker drift og betjening skal der skabes beskyttelse mod indirekte bergring gennem afbryder (min. lOA), som vi1 afbryde & kredsl@b med elektriske ledere i fejlsitua-tion. Afbryderen skal indholde en mekanisk betjent kontakt. Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes og mzerkes som shdan. Afbrydere eller kontakter skal overholde en kendt standard som IEC947.

7. Hvor udstyr eller dreksler er maerket med dette symbol, er farlige sp=ndinger normalt forekom-mende bagved. Disse dzksler b#r kun afmonteres, nti forsyningssplendingen er frakoblet og da kun af instmeret servicepersonale.

8. Hvor udstyr eller dreksler er maerket med dette symbol, forefindes meget varme overfIader bagved. Disse daeksler b@r kun afmonteres af instrueret servicepersonale, nti forsyningsspznding er frakoblet. Visse overflader vi1 stadig vwe for varme at ber@re i op ti145 minutter efter fmkobling.

9. Hvor udstyr eller daeksler er maxket med dette symbol, se da i betjeningsmanual for instmktion.

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10. Alle benyttede grafiske symboler i dette udstyr fmdes i Cn eller flere af fglgende standarder EN61010-1, IFC417 & IS03864.

BELANGRIJK

Veiligheidsinstructies voor de bedrading en installatie van dit apparaat.

Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden. Ook niet EU lidstaten dienen zich aan het volgende te houden, tenzij de lokale wetgeting anders voorschrijft.

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Alle voorziene inteme- en exteme aardaansluitingen dienen op adequate wijze aangesloten te worden.

Na installatie,onderhouds- of reparatie werkzaamheden dienen alle beschermdeksels ikappen en aardingen om reden van veiligheid weer aangebracht te worden.

Voedingskabels dienen te voldoen aan de vereisten van de normen IEC 227 of JEC 245.

Alle bedrading dient~geschit te zijn voor gebmik bij een omgevings temperatour boven 75°C.

Alle gebroikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een adequate verankering van de kabel wordt verkregen.

Om een veilige werking van de apparahmr te waarborgen dient de voeding uitsluitend plaats te vinden via een meerpolige automatische zekering (min.lOA) die g& spanningvoerende geleiders verbreekt indien een foutconditie optreedt. Deze automatische zekering mag ook voorzien zijn van een mechanisch bediende schakelaar. Bij het ontbreken van deze voorziening dient een andere als zodanig duidelijk aangegeven mogelijkheid aanwezig te zijn om de spanning van de apparatuur af te schakelen. Zekeringen en schakelaars dienen te voldoen aan een erkende standaard zoals IEC 947.

Wax de apparahmr of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kmmen zich hieronder spanning voerende delen bevinden die gevaar op kunnen leveren. Deze beschermdeksels/kappen mogen uitsluitend verwijderd worden door getraind personeel als de spanning is afgeschakeld.

8. Waar de apparahmr of de beschenndekselsflcappen gemarkeerd zijn met het volgende symbool, kmmen zich hieronder hete oppervlakken of onderdelen bevinden. Bepaalde delen kmmen mogelijk na 45 min. nog te heet zijn om aan te &en.

9. Wax de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, dient men de bedieningshandleiding te raadplegen.

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10. Alle grafische symbolen gebmikt bij dit produkt zijn volgens een of meer van de volgende standaarden: EN 61010-1, IEC 417 & IS0 3864.

Turvailisuusohje, jota on noudatettava t&n511 l&teen asentamisessa ja kaapeloinnissa.

Seuraavat ohjeet piiteviit erityisesti EU:n jlisenvaltioissa. Niitii tiytyy ehdottomasti noudattaa jotta t5ytettSisiin EUm matalaj%mitedirektiivin (Low Voltage Directive) yhteensopivuus. My& EU:hun kuulumattomien valtioiden tulee nowdattaa titii ohjetta, elleivtit kansalliset standardit esti sit%

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RiittWtt maadoituskytkenn?it on tehMv% kaikkiin maadoituspisteisiin, sis%isiin ja ulkoisiin.

Asennuksen ja vianetsinntin jglkeen on kaikki suojat ja suojamaat asennettava takaisin pai-koilleen. Maadoitusliittimen kunnollinen toiminta tiiytyy aina yllZpit~%

Jtinitesy&t6johtimien f&ytyy t?iytt&? IEC227 ja IEC245 vaatimukset.

Kaikkien johdotuksien tulee toimia >75”C 18impijtiloissa.

Kaikkien lapivientiholkkien sistialkaisijan fiytyy olla sellainen ettX kaapeli lukkiutuu kun-nolla kiinni.

Turvallisen toiminnan varmistamiseksi t%ytyy j%nnitesyBttB varustaa huvakytkimell% (min lOA), joka kytkee irti kaikki jtinitesytittiijohtimet vikatilanteessa. Suojaan tiytyy my& sis%lty% mekaaninen erotuskytkin. Jos ei, niii jtinitesy6tt6 on pystyttiivti katkaisemaan muilla keinoilla ja merkitt&+i siten ett% se tunnistetaan sellaiseksi. Turvakytkimien tai kat-kaisimien tgytyy ttiytm IEC947 standardin vaatimukset n%kyvyydest%

Mii%li laite tai kosketussuoja on merkitty till% merkilti on me&inn& t&ma tai alla hengenvaarallisen suuruinen jsnnite. Suojaa ei saa poistaa jinniteen ollessa kytkettyns laitteeseen ja poistamisen saa suorittaa vain alan asian-hmtija.

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Mikai laite tai kosketussuoja on merkitty til8: merkills on me&inn& takana tai alla kuuma pinta. Suojan saa poistaa vain alan asianhmtija kun j&mite-syiittij on katkaista. Tgllainen pinta voi s%ilyi kosketaskuumana jopa 45 mi-nuuttia.

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Mik%li laite tai kosketassuoja on merkitty ttiti merkillii katso lisiiohjeita kiiyt- teohjekirjasta

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10. Kaikki t&X tuotteessa Hytetyt graafiset symbolit ovat yhdestii tai useammasta seuraavis-ta standardeista: EN61010-1, IEC417 & IS03864.

IMPORTANT

Consignes de s&wit6 concernant le raccordement et l’installation de cet appareil.

Les consignes de s&wit6 ci-dessous s’adressent particali~rement A tow les hats membres de la communaut6 europ6enne. Elles doivent iXre strictement appliqks afin de satisfaire aux directives concernant la basse tension. Les kats non membres de la communautk europ6enne doivent hgalement appbquer ces conslgnes saaf SI elles sent en contradiction avec les standards locaux ou nationaux.

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Un raccordement adgquate a la terre doit &tre effectuke ?I chaque borne de mise a la terre, inteme et exteme.

Apr&s installation ou dkpannage, tous les capots de protection et mutes les prises de terre doivent &tre remis en place, toutes les prises de terre doivent &tre respect&s en permanence.

3. Les &bibles d%mentation &ctrique doivent &re conformes aux normes IEC227 ou IEC245

4. Tous les raccordements doivent pouvoir supporter one tempCratore ambiante sup&ieure 2 75°C.

5. Tous les presse-Moupes utilisCs doivent avoir un diam&re inteme en rapport avec les csbles afin d’assurer un serrage correct sur ces demiers.

6. Afin de garantir la s&u&? do fonctionnement de cet appareil, le raccordement a l’alimentation Sxtrique doit &tre r&lid exclusivement au travers d’un disjonctenr (minimum lOA.) isolant tout les conducteurs en cas d’anomalie. Ce disjoncteur doit kgalement pouvoir &tre actionng manuellement, de faGon mkmique. Dans le cas contraire, un autre syst&ne doit &re mis en place afin de pouvoir isoler I’appareil et doit &re signalis& comme tel. Disjoncteurs et intermpteurs doivent &tie conformes Bone norme reconnue telle IEc947.

7. Lorsque les kquipements ou les capots affichent le symbole suivant, cela signifie que des tensions dangereuses sent prkntes. Ces capots ne doivent &tre d&non& que lorsque I’alimentation est coupke, et uniquement par on personnel compttent.

8. Lorsque les Lquipements ou les capots affichent le symbole suivant, cela signifie que des surfaces dangereusement chaudes sent prkentes. Ces cap&s ne doivent &tre d&monk& qoe lorsque l’alimentation est coupLe, et uniquement par on personnel comp&ent. Certaines surfaces peuvent rester chaudes jusqu’k 45 mn.

9. Lorsque les Cquipements ou les capots affichent le symbole suivant, se reporter au manuel d’instroctions.

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10. Tous les symboles graphiques utilids dans ce produit sent conformes g on ou plusieurs des standards suivants: EN61010-l.lEC417 & ISO3864.

Wichtip:

Sicherheitshinweise filr den Anschlul3 und die Installation dieser Gergte.

Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europtischen Gemeinschaft giiltig. Sie miissen strickt eingehalten werden, urn der Niederspannungsriehtlinie zu geniigen. Nichtmitgliedsstaaten der europiiischen Gemeinschaft sollten die national giiltigen Normen and Richtlinien einhalten.

1. Alle intern und extem vorgesehenen Erdungen der Geri%e miissen ausgefiihrt werden.

2. Nach Installation, Reparatur oder sonstigen Eingriffen in das Gerit miissen alle Sicherheitsabdeckungen und Erdungen wieder installiert werden. Die Funktion aller Erdverbindungen darf zu keinem Zeitpunkt gestiirt sein.

3. Die Netzspannungsversorgung mu8 den Anfordemngen der IEC227 oder IEC245 geniigen.

4. Alle Verdrahtongen sollten mindestens bis 75 “C ihre Fur&ion dauerhaft efillen.

5. Alle Kabeldurchfiihrungen und Kabelverschraubungen sollten in Ihrer Dimensionierung so gewtilt werden, daU diese eine sichere Verkabehmg des Gerstes ermiiglichen.

6. Urn eine sichere Funktion des GerXtes zu gewtirleisten, mu0 die Spannungsversorgung iiber mindestens 10 A abgesichert sein. Im Fehlerfall mu13 dadurch gewtirleistet sein, daf3 die Spannungsversorgung zum Gertit bzw. zu den Ger&ten unterbrochen wird. Ein mechanischer Schutzschalter kann in dieses System integriert werden. Falls eine derartige Vorrichtung nicht vorhanden ist, mu!3 eine andere Maglichkeit zur Unterbrechung der Spannungszufuhr gewtirleistet werden mit Hinweisen deutlich gekennzeichnet werden. Ein solcher Mechanismus zur Spannungsunterbrechung mu!3 mit den Normen und Richtlinien fir die allgemeine Installation van Elektrogerzten, wie zum Beispiel der lEC947, iibereinstimmen.

7. Mit dem Symbol sind Gergte oder Abdeckungen gekennzeichnet, die eine geftirliche (Netzspannung) Spannung fiihren. Die Abdeckungen dtien nor entfernt werden, wenn die Versorgungsspannung unterbrochen worde. NW geschultes Personal darf an diesen Gersten Arbeiten ausfihren.

8. Mit dem Symbol sind GerXte oder Abdeckungen gekennzeichnet, in bzw. unter denen heiBe Teile vorhanden sind. Die Abdeckungen d&fen nor entfernt werden, wenn die Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen Geriten Arbeiten ausfiihren. Bis 45 Minuten nach dem Unterbrechen der Netzzufuhr kannen derartig Teile noch iiber eine erh6hte Temperatur verfiigen.

9. Mit dem Symbol sind GerXte oder Abdeckungen gekennzeichnet, bei denen vor dem Eingriff die entsprechenden Kapitel im Handbuch sorgfgltig durchgelesen werden mtissen.

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10. Alle in diesem Gerit verwendeten graphischen Symbole entspringen einem oder mehreren der nachfolgend aufgefihrten Standards: EN61010-1, IEC417 & IS03864.

IMPORTANTE

Norme di sicurezza per il cablaggio e I’installazione dello strmnento.

Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell’Unione Europea, la cui stretta osservanza 6 richiesta per garantire conform&$ alla Direttiva de1 Basso Voltaggio. Esse si applicano anche agli stati non appartenenti all’unione Europea, salvo quanta disposto dalle vigenti normative locali 0 nazionali.

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Collegamenti di terra idonei devono essere eseguiti per tutti i punti di messa a terra intemi ed estemi, dove previsti.

Dopo l’installazione o la localizzazione dei guasti, assicurarsi the tutti i coperchi di protezione siano stati collocati e le messa a terra siano collegate. L’integriti di ciscun morsetto di terra deve essere costantemente garantita.

I cavi di alimentazione della fete devono essere second0 disposizioni IEC227 o IEC2.45.

L’intero impianto elettrico deve essere adatto per use in ambiente con temperature superiore a 75°C.

Le dimensioni di totti i connettori dei cavi utilizzati devono essere tali da consentire un adeguato ancoraggio al cave.

Per garantire un sicuro funzionamento dell0 stmmento il collegamento alla rete di alimentazione principale dovrk essere eseguita tramite intenvttore automatic0 (min.lOA), in grade di disattivare tutti i conduttori di circuito in case di guasto. Tale intenuttore dovr& inoltre prevedere un sezionatore manuale o altro dispositivo di interruzione dell’alimentazione, chiaramente identificabile. Gli interruttori dovranno essere conformi agli standard riconosciuti, quali IEC947.

11 simbolo riportato sullo strumento o sui coperchi di protezione indica probabile presenza di elevati voltaggi. Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo stmmento.

I1 simbolo riportato ~110 strumento o sui coperchi di protezione indica rischio di contatto con superfici~ad alta temperatora. Tali coperchi di,protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento. Alcune super&i possono mantenere temperature elevate per oltre 45 minuti.

9. Se lo strumento o il coperchio di protezione riportano il simbolo, fare riferimento alle istmzioni de1 manuale Operatore.

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10. Tutti i simboli grtici utilizzati in questo prodotto sono previsti da uno o pib dei seguenti standard: EN61010-1. IEC417 e IS03864.

VIKTIG

Sikkerhetsinstruks for tllkobling og installasjon av dette utstyret.

F0lgende sikkerhetsinstraksjoner gjelder spesilikt alle EU medlemsland og land med i E@S-avtalen. Instruksjonene skal f@lges n#ye slik at installasjonen blir i henhold til lavspennlngsdirektivet. Den b@r ogs& ffdges i andre land, med mindre annet er spesifisert av lokale- eller nasjonale standarder.

1. Passende jordforbindelser m% tilkobles alle jordingspunkter, inteme og eksteme hvor disse forefinnes,

2. Etter installasjon eller feilsgking skal alle sikkerhetsdeksler og jordforbindelser reetableres. Jordingsforbindelsene nG alltid holdes i god stand.

3. Kabler fra spenningsforsyning skal oppfylle kravene spesifisert i IEC227 eller IEC245.

4. Alle ledningsforbindelser skal were konstmert for en omgivelsestemperator hoyere en 750C.

5. Alle kabelforskmvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig avlastning oppnies.

6. For i oppni sikker drift og betjening skal forbindelsen til spenningsforsyningen bare skje gjennom en strembryter (minimum 1OA) som vi1 bryte spenningsforsyningen til alle elektriske kretser ved en feilsituasjon. Strplmbryteren kan ogsi inneholde en mekanisk operert bryter for L isolere instmmentet fra spenningsforsyningen. Dersom det ikke er en mekanisk operert bryter installert, rni det were en annen mite ?I isolere utstyret fra spenningsforsyningen, og denne mitten rni wre tydelig merket. Kretsbrytere eller kontakter skal oppfylle kravene i en annerkjent standard av type” IEC947 eller tilsvarende.

7. Der hvor utstyr eller deksler er merket med symbol for farlig spenning, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene rni bare fjaemes nti spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell.

8. Der hvor utstyr eller deksler er merket med symbol for meget varm overflate, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene m&bare fjlemes II& spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell. Noen overflater kan were for varme til B bereres i opp ti145 minutter etter spenningsforsyning frakoblet.

9. Der hvor utstyret eller deksler er merket med symbol, vennligst referer til instmksjonsmanualen for instmkser.

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10. Alle grafiske symboler brukt i dette produktet er fra en eller flere av f@lgende standarder: EN61010-1, IEC417 & IS03864.

IMPORTANTE

Instru@es de seguranqa para ligqiio e instala@o desk aparelho.

As seguintes instru@es de seguranga aplicam-se especificamente a todos OS estados membros da UE. Devem ser observadas rigidamente por forma a garantir o cmnprimento da Directiva sobre Baixa Ten&o. Relativamente aos estados que n5o pertengam B UE, deverSio cumprir igualmente a referida directiva, exceptuando OS cases em que a legisla@o local a tiver substitaido.

1.

2.

Devem ser feitas liga@es de terra apropriadas a todos OS pontos de terra, intemos ou extemos.

Ap6s a instala@o ou eventual repara@o, devem ser recolocadas todas as tampas de seguransa e terras de protec@o. Deve manter-se sempre a integridade de todos OS terminais de terra.

3. OS cabos de alimenta@o elktrica devem obedecer is exigEncias das normas IEC227 ou IEC2.45.

4. OS cabos e fios utilizadosnas liga@es elktricas devem ser adequados para utiliza@o a uma temperatura ambiente ati 75” C.

5.

6.

As dimensdes intemas dos buck dos cabos devem ser adequadas a uma boa fixaGio dos cabos.

Para assegurar urn funcionamento seguro deste equipamento, a liga@o ao cabo de alimentaqzo ektrica dew ser feita atrav6 de urn disjuntor (min. 1OA) que desligara todos OS condutores de circuitos durante uma avaria. 0 disjuntor poderA tamb&n canter urn interruptor de isolamento accionado manualmente. Caso contrkio, deveri ser instalado qualquer outro meio para desligar o equipamento da energia ektrica, devendo ser assinalado convenientemente. OS disjuntores ou interruptores devem obedecer a uma norma reconhecida, tipo IEC947.

I. Sempre que o equipamento ou as tampas contiverem o simbolo, 6 prov&vel a existkcia de tens6es perigosas. Estas tampas s6 devem ser retiradas quando a energia elktrica tiver sido desligada e por Pessoal da Assist&ncia devidamente treinado.

8. Sempre que o equipamento ou as tampas contiverem o simbolo, hi perigo de existencia de superficies quentes. Estas tampas s6 devem ser retiradas por Pessoal da Assistikcia devidamente treinado e depois de a energia ektrica ter sido desligada., Algumas superficies permanecem quentes at& 45 minutes depois.

9. Sempre que o equipamento ou as tampas contiverem o sfmbolo, o Manual de Funcionamento deve ser consultado para obten@o das necesstiias instru@es.

A t a

10. Todos OS simbolos grificos utilizados neste produto baseian-se em uma ou mais das seguintes normas: EN61010-1, IEC417 e IS03864.

IMPORTANTE

Instrocciones de segurldad para el montaje y cableado de este aparato.

Las sigoientes instnxciones de seguridad , son de aplicacion especlfica a todos 10s miembros de la UE y se adjuntaran para cmnplir la normativa europea de baja tension.

1. Se deben preveer con&ones a tierra de1 equipo, tanto extema coma intemamente, en aquellos terminales previstos al efecto.

2. Una VW. finalizada las operaciones de mantenimiento de1 equipo, se deben volver a colocar las cubiertas de seguidad aasi coma 10s terminales de t&a. Se debe comprobar la integridad de cada terminal.

3. Los cables de alimentacion electrica cumpliran con las normas IEC 227 o lEC 245

4. Todo el cableado sera adecuado para una temperatura ambiental de 75°C.

5. Todos 10s prensaestopas seran adecuados para una fijacion adecuada de 10s cables

6. Para un manejo seguro de1 equipo, la alimentacion electrica se realizara a traves de un interruptor magnetotennico ( min 10 A ), el cual desconectara la alimentacion electrica al equip0 en todas sus fases durante un fallo. Los interruptores estaran de acuerdo a la norma IEC 947 u otra de reconocido prestigio,

7. Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica peligrosa, dicho alojamiento solamente se abrira una vez que se haya intemunpido la alimentacion electrica al equip0 asimismo la intervention sera llevada a cabo por personal entrenado para estas labores.

8. Cuando las tapas o el equipo lleve impreso el simbolo, hay superficies con alta temperatura, por tanto se abrira una vez que se haya interrumpido la alimentacion electrica al equip0 por personal entrenado para estas labores, y al menos se esperara unos 45 minutes para enfriar las supetficies calientes.

9. Cuando el equipo o la tapa lleve impreso el simbolo, se consultara el manual de instrucciones. A t .

10. Todos 10s simbolos graficos usados en esta hoja, estan de acuerdo alas siguientes normas EN61010-1, IEC417 & IS0 3864.

VIKTIGT

Siikerhetsfdreskrifter fiir kablage och installation av denna apparat.

FSljande s%kerhetsfiireskrifter sir tilliimpliga fdr samtliga EU-medlemsl%nder. De skall fdljas i varje avseende fiir att iiverensstima med LHgspZmdngs direktivet. Icke EU medlemsltinder skall ocks~ fdlja nedanstiende punkter, Aida de inte iivergrips av lokala eller nationella fdreskrifter.

1.

2.

3.

4.

5.

6.

I.

8.

9.

10

TillWplig jordkontakt skall utf6ras till alla jordade punkter, s%l intemt som extemt dti si erfordras.

Efter installation eller fels&ning skall samtliga stierhetshtiljen och s&erhetsjord &xplaceras. Samtliga jordterminaler mLte h&s obrutna hela tiden.

Matningssptiningens kabel mbte Gverensst%mma med Mreskriftema i lEC227 eller lEC245.

Allt kablage skall vara l%mpligt f6r anv?indning i en omgivningstemperatur hBgre &I 75°C.

Alla kabelfiirskmvningar som anvbds skall ha inre dimensioner som motsvarar adekvat kabelfiirankring.

F6r att s?&erst%lla s&er drift av denna utmstning skall anslutning till huvudstr&nnen endast giiras genom en sgkring (min 1OA) som skall fr?mkoppla & str&nf&ande kretsar n%r &got fel uppsfir. S%kringen kan given ha en mekanisk f&skiljare. Om sz? inte %r fall&, mhte ett annat fiirfarande f& att frtiskilja utmstningen f&n striimfiirsijrining tillhandah%las och klart framgi venom marker&z. S&rina eller omkopplare maste Gverenssttima Led-en g%llande standard sLom t ex &947. - -

DXr utmstning eller hBlje %I markerad med vids&nde symbol Mreliggerisk fi% livsfarlig sptining i r&h&en. Dessa hBljen f& endast avl%gsnas n%ir st&nmen ej %r an&ten till utrostningen - och di endast av utbildad servicepersonal.

Nti utmstning eller h6lje %I markerad med vidstiende symbol fijreligger risk f& br&mskada vid kontakt med uppvinnd yta. Dessa h6ljen f% endast avl%gsnas av utbildad servicepersonal, nti stri%nmen kopplats frh utmstningen. Vissa ytor kan vara mycket varma att vidrijra iven upp till 45 minuter efter avstigning av striimmen.

NL utmstning eller h6lje markerats med vids&nde symbol b6r instruktionsmanualen studeras fijr information.

A

A III

A t . Samtliga gmfiska symboler som fijrekommer i denna prod& firms angivna i en eller flera av fiiljande f&eskrifter:- EN61010-1, IEC417 & ISO3864.

10. oh0 Ta ypocptK6 ~ti@Ao mu Xptjqtonototiat oc am6 TO npoi6v hat on6 &vo ft

wqxoo6~Spa 0116 ?a &rg npbnma: EN61010-1, IEC417 Kat 1503864.

IB-106.510A mhoi

TABLE OF CONTENTS

Section Page

Rosemount Warranty.. ................................................................................................................................................... i

I. GENERAL DESCRIPTION AND SPECIFICATIONS l-1. Introduction .............................................................................................................................................. 1-2. Description ............................................................................................................................................... 1-3. Operation.. ................................................................................................................................................ 1-4. Performance Specifications ...................................................................................................................... l-5. Physical Specifications.. ........................................................................................................................... l-6. Utilities Specifications .............................................................................................................................

l-l l-l 1-2 1-3 l-3 1-5

II. INSTALLATION 2-l. General ..................................................................................................................................................... 2-2. Unpacking and Inspection.. ...................................................................................................................... 2.3. Site Selection and Preparation .................................................................................................................. 2.4. Infrared Receiver Module Installation ...................................................................................................... 2.5. Infrared Source Module Installation ......................................................................................................... 2.6. Flue Gas Temperature Probe Installation ................................................................................................. 2.1. Control Module Installation ..................................................................................................................... Z-8. Electrical Installation.. .............................................................................................................................. 2-9. Purge Air Requirements ...........................................................................................................................

2-1 2-l 2-l 2-2 2-6 2-8 2-9 2-9

2-13

. OPERATIONS AND CONTROLS 3-l. Theory of Operation ................................................................................................................................. 3-2. Description of Major Components ...........................................................................................................

Infrared Source Module ........................................................................................................................ Flue Gas Temperature Probe ................................................................................................................. Infrared Receiver Module .....................................................................................................................

Purge Air/Enclosure Assembly .......................................................................................................... Radiometer Assembly ........................................................................................................................ Power Supply Board .......................................................................................................................... CPU Board .........................................................................................................................................

Control Module.. ................................................................................................................................... 3-3. Description of Controls ............................................................................................................................

lR Receiver Module Controls ............................................................................................................... IR Source Temperature Controller Controls .........................................................................................

ALIGN/RUN Switch (Sl) .................................................................................................................. Intensity Adjustment Potentiometer (R18). ........................................................................................

lR Source Temperature Controller Controls ......................................................................................... Temperature Setpoint Potentiometer ..................................................................................................

Control Module.. ................................................................................................................................... Control Module Display-Upper Display ............................................................................................ Control Module Display-Lower Display.. .......................................................................................... Audible Alarm.. .................................................................................................................................. Keyboard.. ..........................................................................................................................................

3-1 3-4 3-4 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-8 3-8 3-9 3-8 3-8 3-9 3-9 3-9

3-10 3-11 3-13 3-13

Section

TABLE OF CONTENTS (Continued)

Iv.

V.

3-4. Keyboard Functions.. ................................................................................................................................ STORE ENTRY Key ............................................................................................................................ [*I Decimal Point/RBSP TIME Key.. .................................................................................................... O/GAS TEMP Key ................................................................................................................................. COKE Key.. .......................................................................................................................................... l/CAL/OFF Key .................................................................................................................................... 2lSET ZERO Key .................................................................................................................................. 3lRANGE Key ....................................................................................................................................... 2nd KEY/NEXT Key ............................................................................................................................ 4lHOLDlOFF Key.. ............................................................................................................................... 5lSAVE n Key.. ..................................................................................................................................... 6lRBSTORE n Key ................................................................................................................................ USER KEY/PROGRAM Key ............................................................................................................... IlDlAGNOSE Key ................................................................................................................................ S/ALARM 1 Key.. ................................................................................................................................. g/ALARM 2 Key ................................................................................................................................... ACK ALARM/ENABLE/OFF Key .......................................................................................................

3-5. CO Computation ....................................................................................................................................... 3-6. Function Listing and Description ..............................................................................................................

Secondq Functions .............................................................................................................................. Hold Command.. .................................................................................................................................... Hold Flag.. .............................................................................................................................................

3-7. Function Security System ......................................................................................................................... User Locked Function Security ............................................................................................................. Factory Locked Function Security .........................................................................................................

3-X. ..

System Cahbratmn .................................................................................................................................... Zero Calibration Cycle .......................................................................................................................... Automatic Calibration Cycle .................................................................................................................

3.9. Peek and Poke System Memory ................................................................................................................ The Hexadecimal Number System ........................................................................................................ The Hexadecimal System Used by the 5100 .........................................................................................

3-10. How to Change Addresses in Function 60 (Peek&Poke). ....................................................................... 3-l 1. How to Enter Data into an Address in Function 60 (Peek & Poke) ..........................................................

STARTUP AND CALIBRATION 4-l. General ..................................................................................................................................................... 4.2. Pre-Operation Check and Control Settings ............................................................................................... 4-3. Optical Alignment. .................................................................................................................................... 4.4. Initialize Control Module ......................................................................................................................... 4.5. Zero Calibration ........................................................................................................................................

ACCESSORIES 5-l. Interconnect Cable .................................................................................................................................... 5.2. Thermocouple wire.. ................................................................................................................................ 5-3. Source Purge Air Assembly ......................................................................................................................

Theory of Operation .............................................................................................................................. Source Purge Air Assembly with Jet Pumps. ......................................................................................... Source Purge Air Assembly with Blower.. ............................................................................................

Page

3-14 3.14 3.15 3-16 3-17 3.17 3-18 3-19 3-20 3-21 3-22 3-25 3.26 3-21 3-28 3.30 3-30 3-31 3.32 3-38 3-38 3-38 3-38 3-38 3-39 3.39 3.40 3-41 3-41 3-41 3-48 3-49 3-50

4-l 4-1 4-l 4-2 4-6

5-l 5-l 5-l 5-l 5-l 5-3

TABLE OF CONTENTS

S&iOll

VI. CIRCUIT DESCRIPTIONS 6-l 6-2 6-3

6-4

6-5

6-6

6-7

(Continued)

Overview.. ................................................................................................................................................ Temperature Control (Source) .................................................................................................................. Receiver CPU (Central Processor Unit) ...................................................................................................

Description.. .......................................................................................................................................... CPU Section .......................................................................................................................................... Watch Dog Section ............................................................................................................................... Memory Section.. .................................................................................................................................. Address Decoder Section ...................................................................................................................... J/O Section ............................................................................................................................................ Analog Section.. ....................................................................................................................................

Receiver Power Supply Board ................................................................................................................. AC Voltage ........................................................................................................................................... Tl Secondary Voltage.. ......................................................................................................................... AC Voltage ........................................................................................................................................... Solenold Trutcs ...................................................................................................................................... .. Tnac Clrcult for Calibration Source. .....................................................................................................

Control Module CPU ............................................................................................................................... Description.. .......................................................................................................................................... CPU Section .......................................................................................................................................... Watch Dog Section ............................................................................................................................... Memory Section.. .................................................................................................................................. Decoder Section. ................................................................................................................................... II0 Section ............................................................................................................................................

Control Module Output Circuit Board ..................................................................................................... Components Not Used in Output Generation ........................................................................................ Circuit Operation ...................................................................................................................................

Control Module Power Supply.. ............................................................................................................... Tl Transformer ..................................................................................................................................... Alarm Sections ......................................................................................................................................

VII. TROUBLESHOOTING 7-l. Diagnostics Program ................................................................................................................................ 7-2. Fault/Error Alert.. .....................................................................................................................................

Fault Flag .............................................................................................................................................. Audible Alarm.. ..................... . ............................................................................................................... Alarm 3 ................................................................................................................................................. Held Output Flag.. ................................................................................................................................. Hold Flag .............................................................................................................................................. Receiver Startup.. ..................................................................................................................................

7-3. Fault/Error Identification .......................................................................................................................... GelleW.1.. ................................................................................................................................................ Fault Overrides ......................................................................................................................................

7-4. Fault/Error Description ............................................................................................................................ 1-S. Troubleshooting .......................................................................................................................................

Page

6-l 6-l 6-l 6-l 6-3 6-3 6-3 6-3 6-3 6-6 6-6 6-9 6-9 6-9 6-9 6-9 6-9 6-9

6.12 6-12 6-12 6.12 6-13 6-13 6.13 6-16 6-17 6.17 6-17

7-l 7-l 7-l 7-l 7-l 7-l 7-1 7-2 7-2 7-2 l-2 7-2 7-3


Page

l-6 l-6 7-6 7-6

7-10 7-10 7-10 7.10 7-11 7-11 7-11 7-11 7-11 7.12 7-12 7-12 7-12 7.13 7-13 7.13 7-13 7-13 l-35 7-36 7-31 7-31 7-38

Section

7-6. General Troubleshooting of Faults ........................................................................................................... Flow Chart Symbols .............................................................................................................................. Flow Chart Abbrevntlons ..................................................................................................................... Flow Chart Footnotes ............................................................................................................................ More Than One Action in an Action Block.. ......................................................................................... References Made to Addresses in the Memory .....................................................................................

7-7. Guidelines for Fault Codes ....................................................................................................................... Multiple Faults ...................................................................................................................................... Fault Code 1 .......................................................................................................................................... Fault Code 2 .......................................................................................................................................... Fault Code 3 .......................................................................................................................................... Fault Code 4 .......................................................................................................................................... Fault Code 5 .......................................................................................................................................... Fault Code 6 .......................................................................................................................................... Fault Code 7 .......................................................................................................................................... Fault Code 8 .......................................................................................................................................... Fault Code 9 .......................................................................................................................................... Fault Code 10 ........................................................................................................................................ Fault Code 11 ........................................................................................................................................ Fault Code 12 ........................................................................................................................................ Fault Code 13 ........................................................................................................................................ Fault Code 14 ........................................................................................................................................ Troubleshooting System (Receiver) Reset.. ...........................................................................................

7-8. Limits on Voltages and Resistances.. ........................................................................................................ 7-9. To Peek at Address 0000 .......................................................................................................................... 7-10. To Peek at Address 0007.. ........................................................................................................................ 7-l 1. To Peek at Addresses 0001 and OOOZ.. .....................................................................................................

VIII. SERVICE AND NORMAL MAINTENANCE 8.1. Overview .................................................................................................................................................. 8-2. Removal of Source from Stack/Duct.. ...................................................................................................... 8.3. Removal of PCB from Source .................................................................................................................. 8.4. Installation of PCB Assembly to Source.. ................................................................................................. 8-5. Source Test Procedure.. ............................................................................................................................

Coil, Ohmic Value Test (Source) .......................................................................................................... Overall Source Voltage Test of Thermocouples .................................................................................... Function Test (Source) ..........................................................................................................................

8.6. Installation of Source ................................................................................................................................ 8.7. Thermocouple Test Procedure ..................................................................................................................

Procedure A ........................................................................................................................................... Procedure B ...........................................................................................................................................

8.8. Removal/Installation of Radiometer ......................................................................................................... 8.9. Detector Installation Procedure ................................................................................................................ X-10. Dark Level Test of Possible Noisy Detector.. ........................................................................................... 8-l 1. Test and Replacement of Speed Sensor ....................................................................................................

Speed Sensor Test ................................................................................................................................. Removal of Speed Sensor from Radiometer .......................................................................................... Installation of Speed Sensor to Radiometer.. .........................................................................................

8-l 8-J 8-2 8-4 8-5 8-5 8-5 8-6 8-7 8-7 8-8 8-8

8-10 8-12 S-15 8-16 S-16 8-16 8-17


Page

S-17 8-19 8-21 8-22 8-22 8-22 8-23 8-24 8-25 8-25 8-26 8-27 8-28 g-30 8-32 8-33 8-33 8-33 X-34

8-34

8-35

8-35

8-37 8-37 8-38 8-38 8-39 8-39

section

8-12. Removal of Dual Gas Cells with Solenoid ............................................................................................... 8-13. Installation of Dual Gas Cell Assembly.. .................................................................................................. 8- 14. Removal of the Calibration Gas Cell.. ...................................................................................................... 8-15. Installation of the Calibration Gas Cell .................................................................................................... 8-16. Removal, Installation of Chopper Motor.. ................................................................................................

Removal of Chopper Motor .................................................................................................................. Installation of Chopper Motor.. .............................................................................................................

8-17. Test of Chopper.. ...................................................................................................................................... S-18. Removal/Installation of the Calibration Source ........................................................................................

Removal of the Calibration Source ....................................................................................................... Installation of the Calibration Source.. ..................................................................................................

8.19. Receiver CPU Board Replacement.. ......................................................................................................... 8-20. Control Module CPU Board Replacement.. ............................................................................................. 8.21. Calibration of Control Module Output Card ............................................................................................ 8-22. Reference Voltage Adjustment.. ............................................................................................................... S-23. Receiver Alignment Procedure.. ...............................................................................................................

Apply Power to the Infrared Source Module ......................................................................................... Optical Alignment .................................................................................................................................

8.24. Board Replacement .................................................................................................................................. Removal and Installation of Control Module

Power Supply Board ....................................................................................................................... Removal and Installation of the Control Module

Output Circuit Board ....................................................................................................................... Removal and Installation of Control Module

Rear Interface Circuit Board ........................................................................................................... Removal and Installation of Receiver Power

Supply Circuit Board (PCB) ........................................................................................................... Removal and Installation of the Receiver Ribbon Cable.. ..................................................................

8-25. Cleaning of Calcium Fluoride Window .................................................................................................... 8.26. Record Keeping.. ...................................................................................................................................... 8-27. Manual Check of Span Response ............................................................................................................. 8.28. History Log ...............................................................................................................................................

Ix. REPLACEMENT PARTS

X. RETURNING EQUIPMENT TO THE FACTORY

INDEX

LIST OF ILLUSTRATIONS

Figure

l-l. 2-l. 2-2.

2-3. 2.4. 2-5. 2-6. 2.1. 2-8. 2-9. 2-10. 2.11. 2-12. 3-l. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 5-l. 5-2. 6-l. 6-2. 6-3. 6-4. 6-5. 6.6. 6-7. 6-S. 6-9. 7-l. 7-2. 7-3. 1.4. 7-5. 7-6. 7-7. 7-8. 7-9. 7-10. 7.11. 7-12. 7-13. 7.14. 7-15. 7-16. 7-17.

Typical Model 5 100 CO Analyzer System ............................................................................................... Outline and Mounting Dimensions, Infrared Receiver Module with Jet Pump ........................................ Outline and Mounting Dimensions, Infrared Receiver Module

with Purge Air Blower Hose Adapter .................................................................................................... Infrared Receiver Module Installation with Jet Pump ............................................................................... Infrared Receiver Module Installation with Hose Adapter ....................................................................... Outline and Mounting Dimensions, Infrared Source Module ................................................................... Infrared Source Module Installation ......................................................................................................... Flue Gas Temperature Probe Installation ................................................................................................. Control Module Installation.. .................................................................................................................... Electical Installation ................................................................................................................................ Purge Air Pressure and Flow Requirements for Model 5 100 CO Analyzer.. ............................................ Outline and Mounting Dimensions, Purge Air Blower Motor .................................................................. Blower Motor Wiring Connections .......................................................................................................... Spectral Transmittance of CO2 and CO .................................................................................................... Optical Mounting.. .................................................................................................................................... optical components ................................................................................................................................. Primary Signal Processing -- Analog Representation ............................................................................... Signal Processing Block Diagram -- Analog Representation .................................................................... IR Source and Receiver Modules Block Diagram .................................................................................... Control Module Block Diagram ............................................................................................................... IR Receiver Module Controls ................................................................................................................... IR Source Module Temperature Controller .............................................................................................. Control Module Display ........................................................................................................................... Control Module Keyboard.. ...................................................................................................................... Source Purge Air Assembly with Jet Pumps ............................................................................................. Source Purge Air Assembly ...................................................................................................................... Main Source Temperature Control Schematic .......................................................................................... Receiver CPU Circuit Card Schematic ..................................................................................................... Detector Output (Waveform TP- 13) Receiver Card CPU Board .............................................................. Receiver Power Supply Schematic ........................................................................................................... Control Module CPU Circuit Card Schematic .......................................................................................... Control Module Output Circuit Card Schematic ....................................................................................... Duty Cycle (TPl). ..................................................................................................................................... Control Module Power Supply Circuit Card Schematic ........................................................................... Deleted Multiple Faults Flowchart. ........................................................................................................................ Source Temperature Flowchart ................................................................................................................. Flue Gas Temperature Flowchart. ............................................................................................................. Radiometer Temperature Flowchart ......................................................................................................... Cold Junction Temperature Flowchart ...................................................................................................... Intensity Too High Flowchart.. ................................................................................................................. Communication Link Flowchart #l .......................................................................................................... Communication Link Flowchart #2 .......................................................................................................... Intensity Too Low Flowchart. ................................................................................................................... EEPROM Write Error Flowchart ............................................................................................................. Calibration Cell in Beam Flowchart ......................................................................................................... Calibration Source Flowchart ................................................................................................................... Calibration Cycle Aborted by Receiver Unit Flowchart.. ......................................................................... Calibration Cycle Aborted by Control Module Flowchart.. ...................................................................... Receiver in Alignment Mode Flowchart ................................................................................................... No New Data Transmitted Flowchart. ...................................................................................................... System Reset Flowchart ............................................................................................................................

Page

1-l 2-2

2-3 2-4 2-5 2-6 2-7 2-8

2-10 2-12 2-14 2-15 2-16

3-1 3-2 3-2 3-3 3-3 3-5 3-7 3-8 3-9

3-10 3-13 5-2 s-4 6-2 6-4 6-6 6-7

6-10 6-14 6-16 6-18

7-18 l-19 7-20 7-21 7-22 7-23 7.24 7-25 7.26 7-27 7-28 7-29 7-30 7.31 7-32 7-33 7-34

LIST OF ILLUSTRATIONS (Continued)

Figure

8-1. 8-2. s-3. s-4. 8-5. S-6. 8-7. 8-8. 8.9. s-10. 8-11. 8-12. 8-13. 8-14. 8-15. 8-16. 8-17. 8.18. 8-19. X-20. 8-21. 8-22. 8-23. 8-24. 8-25. S-26. S-27. X-28. 8-29. 8.30. 8-31. 8-32. 8.33. 8-34. 8-35. 8-36. 8.37. 8-38. 8.39. 8-40. 8.41. 8-42. 8-43. s-44. 8-45. 8-46. s-47. S-48.

Hardware Locater Source ......................................................................................................................... Intermediate Source.. ................................................................................................................................ Temperature Control Circuit Board (Stack) ............................................................................................. Voltage Warning Cover and Insulator Board ........................................................................................... Source Assembly ...................................................................................................................................... Source Temperature Control Wire Points.. ............................................................................................... Temperature Control to Intermediate Source ........................................................................................... Output to Intermediate Source.. ................................................................................................................ TB-2 Source Test Points.. ......................................................................................................................... Radiometer Back Half.. ............................................................................................................................ Radiometer Front Half.. ............................................................................................................................ Deleted Deleted Control Module Keyboard Detachment.. .................................................................................................. Correct vs. Incorrect Detector Installation.. .............................................................................................. Speed Sensor to Receiver ......................................................................................................................... Radiometer Rearview (Cable Clamp). ...................................................................................................... Speed Sensor Location ............................................................................................................................. Radiometer Rearview (Disassembly). ....................................................................................................... Part Locator Dual Gas Cell Subassembly.. ............................................................................................... Removal of Dual Gas Cell ........................................................................................................................ Removal Calibration Gas Cell Subassembly ............................................................................................ Radiometer Front View ............................................................................................................................ Calibration Gas Cell with Solenoid .......................................................................................................... Rearview Radiometer for Chopper Motor Replacement ........................................................................... Chopper Motor ......................................................................................................................................... Deleted ..................................................................................................................................................... Chopper Motor Blade Position ................................................................................................................. Chopper Motor ......................................................................................................................................... Chopper Motor Test Set-Up ..................................................................................................................... Subassembly Locator Receiver (Reference) ............................................................................................. J4/Jl Locator ............................................................................................................................................ Deleted Control Key Board Removal .................................................................................................................... Control Module Circuit Locator ............................................................................................................... Voltmeter to Control Voltage Output Rear Interface Board ..................................................................... Control Module Output Circuit Board ...................................................................................................... Current Meter to Control Module Output ................................................................................................. Voltmeter to TP6 (Reference Voltage) Receiver ...................................................................................... Receiver Alignment Adjustment Locator ................................................................................................. Infrared Source Module, Exploded View ................................................................................................. Infrrared Receiver Module, Exploded View .............................................................................................. Infrared Receiver Module, Exploded View.. ............................................................................................ Infrared Receiver Module, Exploded View.. ............................................................................................ Control Module, Exploded View. ............................................................................................................. Gas Temperature Probe ............................................................................................................................ Subassembly, Electronics Main Source Temperature Control .................................................................. Subassembly, Lower Circuit Card Main Source

Temperature Control .............................................................................................................................

Page

8-l 8-2 8-2 8-3 8-4 8-6 8-6 s-7 8-8

8-11 S-11

8-12 8-13 8-16 8-16 8.17 8-18 8-18 8-19 8-21 8.21 8-22 8-23 8-24 8-25 8-24 8-24 8-25 8-26 8-27

8-28 8-29 8.30 8-31 8-32 8-32 8-33 8.40 8-41 8-42 8-42 8-43 8-43 s-44

8-45

SECTION I. GENERAL DESCRIPTION AND SPECIFICATIONS

l-l. INTRODUCTION. The importance of controlling excess air levels in various combustion processes has been recognized for many years. Recently however, the rising cost of fuel has made it an economic necessity to reduce excess air levels to minimize thermal stack losses. Efforts toward combustion efficiency optimization, however, must be aimed at reducing total energy loss. This requires achieving minimum unburned combustibles as well as minimum thermal stack losses. More precise control of the air/fuel ratio, optimized for minimum total energy loss, can yield significant gains in efficiency and result in substantial savings in reduced fuel consumption.

Flue gas concentration of carbon monoxide is a reliable and accurate indication of burner flame stoichiometry and the completeness of combustion. It is the most sensitive indicator of unburned combustibles losses. Used either as a primary combustion efficiency parameter, or in conjunction with oxygen analysis, carbon monoxide offers significant advantages in controlling combustion at optimum levels of excess air. Controlling air/foe1 ratio to an optimum level of carbon monoxide assures minimum total energy loss, and maximum efficiency, independent of variations in boiler load, fuel type, and fuel quality. The measurement is relatively unaffected by air in-leakage and burner maintenance requirements are immediately identified.

The Model 5100 CO Analyzer sets new and superior standards of quality and reliability in providing the many benefits of continuous flue gas carbon monoxide measurement.

1-2. DESCRIPTION. The Rosemount Model 5100 CO Analyzer (Figure l-l) is designed to continuously measure CO concentration levels in combustion flue gases. The analyzer consists of four main components: an infrared source module, an infrared receiver module, a flue gas temperature probe, and a control module. The source, temperature probe, and receiver are installed directly on the flue gas duct or stack, eliminating the need for a costly and complex sample conditioning system. The receiver is positioned to view the source by sighting across the duct, through the flue gas to be monitored. The control module is designed for panel mounting in the boiler control room.

2

ITEM DESCRIPTION

1 IR Source Module 2 3 4

Figure l-l. Typical Model 5100 CO Analyzer System

rE1c&mA l-l

The IR source is housed in a rugged, fully insulated, stainless steel and aluminum enclosure. This enclosure is housed in a carbon steel mounting sleeve designed for welding directly to the duct. Weighing only 33 pounds (15.0 kg), the IR source module is easily installed with a line connection to an AC power source and a thermocouple lead back to the receiver. In normal applications no purge air is required to maintain source cleanliness. However, in certain applications the flue gases contain constituents which can adhere to the source and damage it through corrosion; in these applications a source purge air is required. An optional jet pump is available. The jet pump uses pressurized, low volume plant air to induce a high volume, low pressure ambient air purge through the purge assembly. When pressurized air is not available for the jet pump, the Model 5100 may be equipped with an optional blower accessory. Refer to paragraph 5-3 for a description of the source purge air assembly.

The IR receiver is housed in an epoxy-coated, cast aluminum enclosure. Like the source, the receiver is lightweight, weighing 33 pounds (15.0 kg), facilitating installation. Contained within the receiver are the optics and detector system, startup adjustments and signal processing electronics. The receiver incorporates an automatic calibration system which may be activated from the control module. Signal and power connections are made via terminal strips located in the interior of the enclosure. Should the application require purge air to maintain clean window cleanliness, the Model 5100 is available with an optional jet pump. In negative duct pressure applications, ambient air is naturally drawn into the jet pump, filtered, passed through the purge assembly and into the duct. In positive duct pressure applications, pressurized, low volume plant air is supplied to the jet pump to induce a low pressure., high volume of ambient purge air through the purge assembly. If plant air is not available the Model 5100 may be provided with an optional air blower accessory.

The air,bIower accessory or plant ,&r must ,be provided ‘if pressure in tbe,duct is not always a negative pressure. F&IT to do so may aIIow high i@emaI tempaatnks to be reached in the infrared receiver causing damage to tIje equipment, or shorten its 0perationaI fifespan.

The control module provides control room access to all analyzer functions, intelligent control of all operating functions, and complete remote diagnostic capability. The module is housed in a stainless steel enclosure, with integral, self-attaching, panel-mount hardware. An RS-232 option is available for output to a PC.

1-3. OPERATION. The Model 5100 utilizes infrared absorption spectroscopy to continuously measure CO concentrations in combustion flue gases. The IR source module is mounted directly on the flue gas duct or stack on the side opposite the IR receiver module. Infrared energy is radiated by the source, through the flue gas, to the receiver. The receiver employs gas filter correlation and narrow bandpass optical filtration with a solid state detector to determine the absorption of radiation by CO in the flue gas. CO concentration levels are computed by digital signal processing circuitry and displayed on the control module. Analog output signals of 4-20 mADC, 1-5 VDC, O-20 mADC or O-5 VDC, proportional to measured CO concentration, are generated of input to a recording and/or combustion control system.

1-4. PERFORMANCE SPECIFICATIONS.

Measuring Range ..................................

Optical Path Length ....................................

Flue Gas Temperature ....................................... Flue Gas Opacity .............................................. Accuracy ........................................................... Repeatability ..................................................... Discrimination Ratms ........................................

Time Constant.. ................................................. Analog Output ..................................................

Display .............................................................. Alarms ..............................................................

RS-232 Output (Optional) ..________.............

Continuously adjustable, O-200 to O-10,000 ppm (optical path length dependent)’ 1.5 to 40 feet (0.46 to 12.2 m); distance, source to receiver 200” to 600°F (93” to 316°C) Less than 30% opacity ?20 ppm *6% of reading +lO ppm +3% of reading COz:CO, minimum 10,OOO:l. H,O:CO, minimum 10,000:1 5 to 255 seconds, selectable from control module 4-20 mADC, O-20 mADC (600 ohms maximum load); isolated, field selectable Dual LCD with statlls, fault, and alarm flags Two highnow alarms, solid state relays, 3 amp, AC, maximum rating; 170 watts resistive. One arm relay, SPDT; 780 VA inductive, 260 volts. Audible alarm (control module). Visual alarm flags (control module). Fault codeslppm CO on request if the program is initiated by the PC.

‘Maximum full scale operating range to which the analog output is automatically scaled is a function of optical path length. For a given application, the product of the full scale concentration and the optical path length may not exceed 33,ooO ppm-ft (10,000 ppm-m).

Example: Optical path length = 20 feet.

Maximum full scale operating range = 33,ooO ppm-ft. = 1,650 ppm 20 ft.

1.5. PHYSICAL SPECIFICATIONS.

Infrared Source Module

Enclosure .......................................................... Dimensions ....................................................... Electrical Connections.. .................................... Mounting ..........................................................

Net Weight.. ...................................................... Ambient Temperature .......................................

Stainless steel, carbon steel and cast aluminum 18 in. (457 mm) length; 10 in. (254 mm) diameter Terminal strips for power and thermocouple extension S-inch (203 mm) Schedule 5S carbon steel mounting sleeve (Rosemount supplied) 33 lbs (15.0 kg) -20” to 130°F (-29” to WC)

Infrared Receiver Module

Enclosure.. ....................................................... Dimensions.. ................................................... Electrical Connections.. ..............................

Distance, Receiver to Control Module.. ........................................... Mounting.. .......................................................

Purge Air Fitting (Jet Pump Only). ....... Net Weight.. .................................................... Ambient Temperature.. ..............................

Control Module

Enclosure.. ....................................................... Dimensions.. ...................................................

Electrical Connections.. .............................. Mounting.. ....................................................... Net Weight.. .................................................... Ambient Temperature.. ..............................

Flue Gas Temuerature Probe

Enclosure.. ....................................................... Probe Dimensions.. ...................................... Electrical Connections.. .............................. Mounting.. ....................................................... Net Weight.. ....................................................

Blower Motor

Air Flow (max). ....................................... Dimensions.. .............................................

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

lP56b’EMA 4, zinc-plated steel 12 x 12 x 16 in. (305 x 305 x 406 mm) HWD Terminal strips for power, thermocouples and RS-422 communication

1 mile (1.61 km) maximum To customer-supplied flange: ANSI B16.5 4-inch (100 nun), 150 lb, flat face, weld neck flange with four 3/4-in. bolt holes, 4 in. diameter center hole l/4 in. (6.35 mm) OD tube 33 lbs (15.0 kg) -20’ to 1300F (-29” to 55OC). Temperature of the optical system must not fall below dewpoint

EMC Rated Eurorack, rack or panel mounting 5.22 x 10.61 x 11.62 in. (1325 x 269,5x 295 nun) (H x W x D) Terminal strips for power, and all signals Rack or Panel Mount 6 Ibs. (2.7 kg) 32’to 104? (0” to 40%)

Cast aluminum head; Inconel sensor probe. l/4 in. (6.35 mm) dia x 36 in. (914 mm) length Terminal strip l/2-inch NPT 1 lbs (0.45 kg)

40cfm@10in. 0 3 Height 10 inches 54 nun)

Width 9.8 inches (249 nun) Depth 11.1 inches (282 mm) 29 pounds (13,l Kg)

1-6. UTILITIES SPECIFICATIONS.

Electrical Classification _........_...........

Infrared Source Module

category Il

Power 100.130/200-260 VAC, 50/60 Hz; 550 watts nominal (1300 watts maximum)

Infrared Receiver Module

Power . . . . . . . . . . . . . 100.130/200-260 VAC, 50/60 Hz; 125 watts Purge Air

1. Negative duct pressure-none required 2. Positive duct pressure-see Figure 2-10 for flow and pressure requirements

Control Module

Power .._.....................................

Blower Motor

100.130/200-260 VAC, 50/60 Hz: 20 watts

Power lOO-130/200-260 VAC, 50/60 Hz, 400 watts

SECTION II. INSTALLATION

2-l. GENERAL.Tbis section describes the procedures required for installation of the Model 5100 CO Analyzer.

2-2. UNPACKING AND INSPECTION. Inspect the shipping container and notify the carrier immediately if any damage is detected. Open the shipping container and inspect the individual analyzer components for damage.

2-3. SITE SELECTION AND PREPARATION. Observe the following guidelines when selecting a site for the unit.

a. Select readily accessible positions for the IR receiver, lR source, and temperature probe on the duct or stack to allow for routine maintenance. Periodic access to the receiver is particularly important. Comfort levels for maintenance personnel should be a consideration in placement of the receiver unit.

b. The site should be free from excessive vibration and the ambient temperature for the source and receiver modules must be within -20’ to 130°F (-29” to 55°C).

NOTE

To avoid condensation, the temperature of the optical system should not be allowed to fall below the water dewpoint temperature.

c. The flue gas temperature should be in the range of 200” to 600°F (93” to 316°C).

d. The flue gas opacity should not exceed 30%.

e. The site should be downstream of any particulate removal device (e.g., electrostatic precipitator) to assure minimum flue gas opacity.

f. The site should be upstream of any wet scrubbing device (e.g., wet flue gas desulfurization system) to assure minimum entrained liquids in the flue gas.

g. The site should not be immediately down-stream of sharp bends in flue gas ductwork.

h. The site chosen for the receiver must be opposite a suitable site for the source

2-4. INFRARED RECEIVER MODULE INSTALLATION.

a. Provide an ANSI B16.5 4inch (100 mm) 150 lb, flat-face weld neck llange with four 3/4 inch bolt holes, 4 inch diameter center hole, or equivalent connection to the duct or stack. For mounting dimension refer to Figure 2-I for IR receiver modules with jel pumps, or Figure 2-2 for IR receiver modules with hose adapters.

Damage to tbe receiver will result from hot flue gases if tbe slide window assembly is not fidIy positioned against either of its stops.

MXES: “NESS OMEmvlSE SPEClRED

Figure 2-2. Outline and Mounting Dimensions, Infrared Receiver Modules with Purge Air Blower Hose Adaptor

Receiver contains an internal calibration source that is heated to 1100°F (593°C); therefore it is not suitable for installation in Class I, Division 2, areas.

Damage to the receiver will result from hot flue gases if the slide window assembly is not fully positioned against either of its stops.

Damage to receivers mounted on positive pressure ducts will result via transmission of hot flue gases if blower motor is not immediately turned on.

b. Attach alignment flange (2, Figure 2-3 or 2-4) and gasket (3) to weld neck flange (4) using bolts (8), flatwashers (5), lo&washers (6), and nuts (7).

c Fit receiver to alignment flange (2) and secure with nuts (10) and lo&washers (9).

d. Complete power and signal connections. Refer to paragraph 2-8.

e. Connect primary purge air supply, if required. Refer to paragraph 2-9

1. Cover 2. Flange 3. Gasket 4. Flange (Customer Supplied) 5. Flat Washer, 5/8 In. 6. Split Lockwasher, S/8 In. 7. Hex Nut, 518-U

8. Bolt, S/8-11 x 25 In. 9. Split Lo&washer, 3/8 In.

10. Hex Nut, 3/8-16 11. Slide Window Assembly 12. Jet Pomp 13. Purge Air Filter 14. washer 15. Spool Piece (Customer Supplied)

Figure 2-3 Infrared Receiver Module Installation with Jet Pump

IBlC&SlOA 24

1. COWX 7. Hex Nut, 518-11 In. 2. Flange 8. Bolt, 5/8-11x 25 In. 3. Gasket 9. Split Lo&washer, 3/8 In. 4. Flange (Customer Supplied) 10. Hex Nut, 3/8-16 5. Flat Washer, 5/8 In. 6. Split Lockwasher, 5/8 In.

11. Slide Window Assembly 12. Purge Air Hose Adaptor 13. Spool Piece (Customer Supplied)

Figure 2-4. Infrared Receiver Module Installation with Hose Adaptor

IElc.5-SloA 2-s

2-5. INFRARED SOURCE MODULE INSTALLATION:

a. Cut the flanged slew to fit the duct or stack and to locate the face of the IR source flush with the inside surface of the duct or stack wall as shown in Figure 2-5.

I o” 0 g$,& 0

D 0

Tl

a 0

0 0 0

O 0 O

b.

e.

d.

e.

Weld modified flanged sleeve (1, Figure 2-6) to the duct or stack.

To install the source, remove cover plate, Figure 2.6, from the sleeve and replace with so”rce module (3), “sing existing gasket (2) and eight l/4-20 bolts (4) and washers (5). (Do not racwe the four socket-head screws holding the rear plate to the inner housing.) Save cover plate in the event that servicing the s”“rce module becomes necessary.

Complete power and signal interconnections. Refer to paragraph 2-8.

Upon completion of installation, if duct insulation is to he replaced, insulate around perimeter of sleeve only. Do not cover either temperature controller housing or rear plate of source module with insulation.

CARSON STEEL

INLESS STEEL

1. Flanged Sleeve 2. Gasket 3. IR Source Module 4. Bolt, 1/4-20x 1.00 I”. 5. Split Lockwasher, l/4 In.

Figure 2.6. Infrared Source Module Installation

The IR Source is a sealed unit containing a manmade mineral fiber know as Fiberfrax. The material is used for insulation purposes. In the event of failure, national and local regulations apply to the disposal of the unit.

2-6. FLUE GAS TEMPERATURE PROBE INSTALLATION.

a. Provide a standard l/z-inch NPT coupling to the stack or duct.

NOTE

For smaller diameter ducts of less than 10 Peet (3 m), a longer coupling may be required to locate the tip of the temperature pmbe in a more representative temperature location. This location is appmximately 25% of the duct diameter into the duct.

b. Weld the coupling to the duct, Figure 2-7. Locate temperature probe below the plane of the IR source and receiver. Ensure that a minimum distance of three feet (1 m) is left between the tip of temperature probe and the IR source.

NOTE

Locating the temperature probe on the IR receiver side of the duct decreases thermocouple cable run distance.

c. Install ungrounded thermocouple and interconnect to receiver. Refer to paragraph 2-8.

Figure 2-7. Flue Gas Temperature Probe Installation

IBlc!&mA 2-s

2-7.

2-8.

CONTROL MODULE INSTALLATION.

a. The control module should be located in an easily accessible area of the control room. Locate in an area free of excessive vibration, and where the ambient temperature is within the range 32” to 104°F (0” to 40°C).

b. Provide a panel cutout of 5.25 x 9.25 in. (133 x 234 mm).

E. Insert control module into panel cutout.

d. Complete power and signal interconnections. Refer to paragraph 2-X.

ELECTRICAL INSTALLATION.

a. In addition to AC power supply lines to the JR source, lR receiver and control modules, the following interconnect cables are required for electrical installation:

1. Interconnect cable, infrared receiver module to control module, 3.conductor, shielded, 22 AWG. For additional information, refer to Section 5.

2. Thermocouple wire, Type K, 24 AWG, infrared source module and flue gas temperature probe to infrared receiver module. For additional information, refer to Section 5.

Four thm holes are located at the base of the IR receiver for cable entry. Two of these arc covered with dust caps and two with weathertight seals. Two to four thm holes may be used, as desired, for electrical connections. Those used should be fitted with sealed conduit fittings. Those not used should remain sealed with the weathertight seals provided.

Three thru holes are located at the rear base of the control module. These are also covered as described above Similar guidelines should be followed for electrical connections.

b. Observe the following during electrical installation:

1. Keep signal cables and thermocouple wires separated from power cables.

2. If signal and power cables must cross, make sure the cables cross at right angles.

3. Keep all cables away from hot objects.

NOTE

To ensure CE compliance, the outer shield of the RS422 Communications cable should be terminated at both ends. At the Control Room Unit (CRU) a ground point is provided on the backplane. On the IR Receiver the cable should he terminated BEFORE entering the enclosure. A GND stud is provided.

A good Earth is essential for the proper operation of the 5100A CO Analyzer. The chassis of the CRU, the outer casing of the IR Receiver, and the mounting plate of the IR Source should all be connected to Earth using the GND stud connections provided.

t D-

EB

Q +1 .o

PANEL CUTOUT g x 234 L PER DIN STANDARD #43700 9.25 +.039

-.ooo

NOTES: UNLESS OTHERWISE SPECIFIED

Figure 2-8. Control Module Installation

lB-106.51OA Z-10

4.

5.

6.

7.

8.

Where there is a possibility of mechanical damage, be sure that the cable is armored, enclosed in a heavy conduit, or protected in a similar fashion.

Avoid or minimize signal cable junctions. Each junction interrupts the shield and renders the output signal more susceptible to electrical noise interference.

The use of a shielded transformer in the AC supply line is recommended where an instrument supply is not available.

See Figure 2-9 for electrical connections for the IR receiver, IR source, temperature probe, and control module.

(a) Remove cover of IR source temperature controller by turning cover counterclockwise.

(b) Remove cover of IR receiver by loosening eight screws. Note that the screws are captive, but the cover detaches completely.

(c) Connect Qpe K thermocouple wire from source to receiver.

(d) Remove screw cap of flue gas temperature probe.

(e) Connect Qpe K thermocouple wire from probe to receiver.

(f) Remove six rear cover screws and rear cover of control module.

(g) Eoyu;;t the 3-conductor, shielded communication cable from the receiver to control

(h) Connect AC power wiring to IR source through external 20 Amp circuit breaker.

(i) Connect AC power wiring to IR receiver through external 2 Amp circuit breaker.

6) Connect AC power wiring to control module through external 1 Amp circuit breaker.

Additional electrical connections may be required from the control module to user-supplied equipment. Control module rear terminal designations and descriptions follow.

(a)

(b)

(4

Cd)

ALM 1.54 Terminals 1, 2. Alarm 1 is a high/low CO concentration alarm, solid state relay, 3A, AC, maximum rating: 170 watts resistive.

ALM 2.55 Terminals 1.2. Alarm 2 is a highnow CO concentration alarm, solid state relay, 3A, AC, maximum rating 170 watts resistive.

Alarm 3, 56 Terminals 1, 2. 3. Alarm 3 is energized under a fault/error condition and in conjunction with Alarm 1 or Alarm 2. Alarm 3 is a relay, SPDT; 780 VA inductive, 260 volts. Analog Outuut Terminals 58. J9. One of four available analog output signals proportional to measured CO concentration is selected using the combination of the appropriate pair of terminals and keyboard procedures.

Current output: 4-20 mADC or O-20 mADC, 600 ohms maximum load. Use 58 terminals l(-) and 2(+).

Voltage outputz O-5 VDC or l-5 VDC, 1000 ohms minimum load. Use J9 terminals 2(-) and l(+).

lB-ice-SlOA 2-11

IR SOURCE MODULE

CONTROL MODULE 214mw2

Figure 2-9. Electrical Installation

IB-106.5lOA 2-12

HOLD COMMAND, Terminal HO. The HOLD COMMAND places the analyzer in a HELD OUTPUT mode of operation. To allow issuance of this command, wire a switch between terminal 1 and terminal 3 (common), paragraph 3.6.b.

HOLD FLAG, Terminal JlO. The hold flag is issued upon entering a held output mode of operation and maintaining throughout the duration of the held output. This is a logic level signal at terminal 2 with respect to common (terminal 3).

Logic level 1: 2.4 VDC minimum for standard TTL input.

Logic level 0: 0.6 VDC maximum at 1.6 mADC maximum sink current, paragraph 3.6.~

RS-232 Terminal ,115. Connect the RS-232 inputs to terminals 1 (IN), 2 (OUT), and 3 (COM). Install diskette lLO4438HOl into the PC and run “51OO.bat”.

2-9. PURGE AIR REOUIREMENTS.

a. M. The presence of paticulates, entrained liquids, etc., in some combustion flue gases may lead to a coating of analyzer optical surfaces exposed to the gases. To reduce the need for periodic manual cleaning of these surfaces (which is required to maintain proper analyzer operation), it is recommended that the surfaces be purged continuously with clean air.

The IR source module is installed with the source surface flush with the inner wall of the duct in most applications. Therefore, the source is subject to only minimal coating or particulate buildup, and consequently there is no purge air requirement to maintain source cleanliness. Purge air is recommended for the IR receiver module to maintain cleanliness of the receiver module window.

b. Negative Duct Pressure Aadications. In these applications, the IR receiver module, fitted with jet pump as shown in Figure 2-1, is self purging. Negative duct pressure will induce ambient air flow through the jet pump. The ambient air is filtered and passes through the purge assembly, by the window, and into the duct. No external air supply is required if the duct pressure never goes positive.

c. Positive Duct Pressure Armlications with Jet Pumps. When the Model 5100 with optional jet pumps is installed on a duct under positive pressure an external, primary purge air supply is required. The jet pump is designed to accept a pressurized, low volume primary air supply to induce a low pressure, high volume flow of filtered ambient air through the purge assembly, by the window, and into the duct.

1. Provide a primary purge air supply, either plant air or compressor. See Figure 2-10 to determine primary supply pressure and flow requirements as functions of maximum expected duct pressure.

NOTE

The low volume primary purge air supply for the jet pump is customer supplied.

2. Using a l/4-inch (6,35 mm) tubing, connect the primary purge air supply to the jet pump through l/4-inch tube fitting per Figure 2.1,

3. Initiate the primary purge air supply and adjust pressure to a level slightly in excess of the minimum primary pressure determined from Figure 2.10. This will assure a positive purge flow under conditions of nomu duct pressure and positive pressure excursions.

9.0 M

a.5 34

a.0 32

7.5 30

1.5 a

1.0 4

05 2

0.0 0

FOR MAXIMUM EXPECTED DUCT PRESSUR.E, SET PRIMARY PRESSURE AT INDICATED

VALUE OR HIGHER

DUCT PREsS”Rr 20’ Hz0 (5.0 kPd

MINIMUM PRIMARY PRESSURE: 37 psi2 f255.1 kP.1

/

EXAMPLE /

PRIMARY AIR CONSUMPTION: 2.22 CFM

7 0 to 20 30

0.0 aa. VS.9 2oa.a 275.8 244.7 412.7

PRIMARY JEY PUMP PRESSURE, KILOPASCALS

Figure 2-10. Purge Air Pressure and FIow Requirements for Model 5100 CO Analyzer

d. Positive Duct Pressure Amlications with Blower. Model .5100 analyzers equipped with purge.‘air blowers, Figure 2-11, provide a contimmus source of bigb volume low pressure air to the receiver hose adaptor, Figure 2-2.

1. Locate the air blower assembly near the module in a location that provides a source of clean fresh purge air. 10 feet of hose is supplied with the blower. Refer to Figore 2-11, for blower mounting dimensions.

2. Connect the blower to the module hose adaptor.

3. Connect the blower motor to ll9220 VAC power source. Run cable through the motor junction box seal fitting and connect as shown in Figure 2-12 Tighten seal fitting onto cable.

poTATl~,v PURGE AIR SLOWER

SLOT 0.41 X 0.44 LG (4 PLACES)

I

’ /I a.112

I I i VENT HOLE 0.375 #THRU

(4 PLACES)

Figure 2-11. Outline and Mounting Dimensions, Purge Air Blower Motor

$1 GREEN

WHlTE WHITE

YELLOW BLACK

BROWN

BLACK

* IN SOME APPLICATIONS THE BLOWER MOTOR 115 VAC UNE WHITE WIRE MAY BE BLUE, AND THE PAACK WIRE MAY SE BROWN.

115 VOLT OPERATION

MOTOR LINE’

GRND - GREEN@ BLUE PI BLACK L WHITE 2-WHlTEN YELLOW - 4

2%;” ORANGE -

115 VOLT WlRlNG CONNECTIONS

YELLOW

BROWN

WHlTE

220 VOLT OPERATION

MOTOR LINE

BLUE STND - mi? ,”

Ek%! 4 WUtTE N

BLACK WHITE ORANGE -

220 VOLT WIRING CONNECTIONS

Figure 2-12. Blower Motor Wiring Connections

SECTION Ill. OPERATIONS AND CONTROLS

3-1. THFZORY OF OPERATION. The Rosemount Model 5100 CO Analyzer operates on the principles of infrared absorption spectroscopy. Heteroatomic molecules exhibit characteristic absorption spectra that are related to the number, configuration, and types of atoms in the molecule; the simpler the molecular structure, the simpler the absorption spectrom. By examination of the infrared spectra of gases, it is possible to locate an infrared absorption region unique to CO or CO,

The Model 5100 is designed such that the window, lens, bandpass filter, pyroelectric detector and other optics are toned to operate in the main absorption band of carbon monoxide. Within this band, still higher selectivity is achieved by correlating the observed spectrum with that of a permanent sample of carbon monoxide. The technique is termed “gas filter correlation spectroscopy”.

The infrared source is heated to approximately 11120F (600°C). This produces an in@red emission in the region of interest, which is between 4.5 and 4.9 microns. The source is mounted on the opposite side of the duct or stack from the receiver. Thus, the energy radiated by the source must pass through the flue gas before being measured by the receiver. The relative percentage of radiation absorbed in the region of interest indicates the level of CO in the flue.

Figure 3-1 shows the relative absorption of CO and CO2 in the band from 4 microns to 5 microns. Figure 3-l also shows the bandpass filter’s transmission relatwe to the absorption of CO and CO, The band from 4.5 to 4.9 microns is selected to maxim& the response to CO. The exact shape of the filter bandpass is chosen to mioimiz the effect of absorption due to CO, and 30 (which absorbs at%ghtly longer wavelengths). The radiant energy in this narrow band is the only energy allowed to impinge on the pyroclectric detector.

Figure 3-1. Spectral Transmittance of CO, and CO

IB-lM-SlOA 3-l

Figure 3-2. Optical Mmmtig

Figurea3-2 and 3-3 are simpliied optical diagrams which show the critical components for determining the infrared energy that passes through the flue gas.

The iofrared source is a large-diameter, staintess steel cyImder which is maintained at a temperatore of approximately lll2’% (HlO”C). It is mounted opposite the IR receiver module. The receiver has a Cal- cium fluoride window to isolate the instrument enclosure from the tlue gas. The germanium lens focuses the infrared energy that has not been absorbed onto the pymelectric detector.

Figure 3-3. Optical Components

SAMP co

co (REF CELL)

HOW SOLENOID

SUMMING AMP

S = AMPLITUDE OF WIDESAND INFRARED SOURCE * A = TRANSMISSMTY OF CO IN THE FLUE AND CO

REFERENCE CELL B = ;~;L~ISSMTY OF THE CO IN THE RUE AND

Figure 3-4. Primary Signal Processing --Analog Representation

Figure 3-4 shows the CO reference gas cell in place in the optical path. One section of the dual gas cell assembly is filled with 100% CO atmospheric pressure and the other section is filIed with 100% nitrogen. Both are sealed with sapphire windows. The pyroelectric detector is a charge-sensitive device which develops a signal with changes in infrared energy. A motor-driven chopper blade is used to interrupt the infrared beam enabling the pyroelectric detector to provide a periodic wave output at 40 Hz. An aperture is placed in front of the detector to limit the field of view to a small area on or around the infrared source. The pyroelectric detector and its associated preamplitier produce a periodic wave signal at the chopper frequency. The amplitude of the signal is proportional to the amplitude of the energy striking the detector within the waveband of 4.5 to 4.9 microns, which is the bandpass of the filter.

Figure 3-5 is an analog representation used to explain how the microprocessor determines the amount of CO in the flue. In order to explain the sequence of events, we will break it up into four steps.

4 4 9 9

Av+P.-. Av+P.-. 510HA.L 510HA.L GAS TEMP. GAS TEMP.

- R*O,OMETER - - R*O,OMETER - - LOEARlIER - - LlNEARIZER - VVVVI VVVVI PROCESsOR PROCESsOR COMPrHS*TlON COMPrHS*TlON vuvv% vuvv%

VOLThOE 6 PAT” LEHOT” __

co otsPL*v OAMP,HO - CURREnT

COYPE,‘SATlOl4 0”TP”T - o-aom* I 4-EOrnA

- O-6” I l4V

Figure 3-5. Signal Processing Block Diagram --.Analog Representation

IB-lee-510.4 3.3

Definitions

s= Level of infrared radiation from the source. A= Combined transmissivity of CO in the flue gas and in the CO reference cell. B= Combined transmissivity of CO in the flue gas and in the N, cell.

NOTE

Nitrogen does not absorb infrared energy. The lcm-atm CO relerence cell absorbs nearly the total amount of energy that can be absorbed by CO. Therefore, the presence of CO in the flue gas, and the associated reduction in transmissivity, will have a proportionally greater effect upon B than upon k

a. Read the cell energy level at the detector with the CO reference cell in the optical path. Store this reading in a sample-and-hold amplifier. We call this stored value SA.

b. Read the energy level at the detector with the N cell in the optical path. Store this reading in a sample-in-hold amplifier. We will call this stored v af ue SB.

c. By inverting the SA signal to get a -SA and adding it, in an inverting summing amplifier, to K(SB), the resulting signal output is S(A-KB), which is a signal that represents the difference between detected energy levels with and without the CO reference gas in the optical path. (The nitrogen gas has no absorption.)

d. The signal S(A-KB) is then divided by SA in a divider circuit to obtain the signal (l-KB/A), which is a function of the CO level in the flue gas. Notice that the amplitude of the source (S) has been can- celled out in the analysis and the output ratio is independent of the source.

The K factor is adjusted such that, when CO is not present in the flue gas, KB=A. The output of the divider is then zero. As CO concentration in the flue gas increases, the ratio of B to A decreases; hence, the term (I-KB/A) increases.

Figure 3-5 shows an analog representation of other adjustments and corrections made to the signal before it is converted to an output signal.

The linearizer circuit is designed to linearize the logarithmic output of the divider. The signal is then corrected for temperature of the flue gas and path length of the flue. The damping circuit is an adjustable filter used to reduce unwanted noise from the signal. At this point the signal is converted to a 4-20 mA, l-5 WC, O-20 mA or O-5 VDC signal that represents a zero-to-full-scale reading.

The theory of operation described above is an analog representation of the operation of the microprocessor-based receiver and control modules. Figures 3-6 and 3-7 are basic block diagrams showing the four major components of the Model 5100 CO Analyzer. Component descriptions are given in the following section.

3-2. DESCRIPTION OF MAJOR COMPONENTS.

a. Infrared Source Module. The source of infrared radiation ia a 4” (10 cm) diameter, stainless steel cylinder heated by a tubular heater coil, The temperature is controlled by a solid state temperature controller. The temperature is measured by two Type K thermocouples. One thermocouple provides a control signal to the triac controller. The second thermocouple allows the microprocessor to monitor source temperature, thereby indicating if the IR source is functioning properly. The temperature is nominally adjusted to 1112’F (6OO’C) for proper operation, but has a limited adjustment range for special applications.

I&105-510.4 3-4

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b. FIue Gas Temperature Probe. The gas temperature is measured with an isolated ungrounded and sheathed Type K thermocouple probe which is supplied with the system. Cold junction compensation is accomplished at the receiver terminal strip.

e. Infrared Receiver Module. The receiver consist of four components. They are:

1. Purge Air/Enclosure Assembly. The purge air assembly provides a means to maintain cleanliness of the calcium fluoride window and to protect the receiver from the adverse effects of corrosive flue gas constituents. Purge air requirements are described in pamgraph 2-9. The NEMA 4, weathertight enclosure provides environmental integrity.

The calcium fluoride window is slider-mounted in the purge air/enclosure assembly. The receiver design is such that a considerable amount of coating on the window can be tolerated. If the window becomes excessively coated, however, this condition is detected as a fault, flagged at the control module and cleaning is necessary. Slider mounting allows for convenient window cleaning. Frequency of window cleaning is significantly reduced by continuous purge air.

2. Radiometer Assembly. The radiometer is a compact optical bench containing a planoconvex germanium lens, narrow bandpass optical filter, pyroelectric detector, field stop aperture, gas cells, calibration source, motor-driven chopper blade and a photo chopper. The gas cells and calibration source are placed into position by long-life rotary solenoids. The chopper motor speed is measured by a photo sensor which sends feedback signals to the central processor unit (CPU).

3. Power Supply Board. The receiver power supply provides low voltage, regulated power to the CPU hoard and radiometer as well as power for the solenoid drives. The drivers for the solenoids and the triac driver for the calibration source are also on the power supply board.

4. CPU Board. The central processor input (CPU) consists of a Motorola 6802 microprocessor with associated memory, peripheral interface adapter, AID converter, data multiplexer and communication device. The CPU provides timing control signals to the solenoid drivers, calibration source and chopper motor drive circuit. It also collects data on signal levels from the pyroelectric detector and temperature data. Formatted data is then transmitted to the control module over an RS-422 interface.

d. Control Module. The control module is a 133 x 234 DIN size, panel-mounted enclosure with an interface board, three plug-in circuit boards and the keyboard/display. The module receives digital data from the IR receiver module and computes the correct output response. Numerous features can be programmed from the front panel keyboard and displayed on the dual liquid crystal display (LCD). For example, analog outputs corresponding to the computed CO concentration can be selected for O-20 mA, O-5 volts, 4-20 mA, or l-5 volts. The CPU contains electrically erasable, programmable, read-only memory (EEPROM) to retain the system set points and operating parameters even after power outages. The CPU continuously scans the keyboard for manual entries as well as updating the display. It also controls the RS-422 communication interface to the IR receiver module and the optional RS-232 output to a PC.

Figure 3-7. Control Module Block Diagram

ELlM51OA 3.1

Figure 3-8. IR Receiver Module Controls

3-3. DESCRIITION OF CONTROLS.

a. IR Receiver Module Controls.

1. ALIGN/RUN Switch (Sl). The ALIGN/RUN switch, Figure 3-8, is placed in the ALIGN position in order to activate the LED alignment display and audible buzzer. In routine Operation, the switch must be kept in the RUN position.

2. Intensity Adjustment Potentiometer (R18). The intensity pot, Figure 3-8, is used to adjust the gain of the detector amplifier to the proper range for the particular installation. Proper gain will be a function of optical path length and flue gas opacity. Clockwise rotation of this potentiometer will increase the level indicated on the LED’s.

b. IR Souree Temoeratnre Controller Controls.

1. Temperature Setpoint Potentiometer. This pot, Figure 3-9, is set at the factory, but there may be a need to adjust the soorce temperature during its service life. A clockwise rotation will increase the temperature setpoint. The nominal setpoint is 1112°F (600%) and this may be increased to 1382oF (750°C).

OR 23OV 50/60 HZ FOR 23OV UNIT ONLY

Figure 3-9. JR Source Module Temperature Contmller

e. Control Modnle. The control module, provides the central interface between the analyzer and the operator, recording, annunciating, data acquisition and control systems The microprocessor iden- tilies data, operating parameters, commands and other internal operations as functions. With the exception of certain command functions, each function is assigned a two-digit function code. Access to functions is through the keyboard. Display of data and various operational states is provided by two liquid crystal display’s (LCD’s). The following sections describe the control module keyboard and functions of the Model 5100 CO Analyzer.

IElM-SlOA 3.9

r ~~~ READING HELD OUTPUT

TEST VALUE

CO analyzer

MAN GAS T

FUNCTION

Figure 3-10. Control Module Display

1. Control Module Display-Upper Display. This is a four-digit liquid crystal display (LCD) which indicates the reading being presented or data being entered from the keyboard. Mnemonics may also appear in this display in selected functions (Figure 3-10).

Display Flags:

(a) Held Output. Indicates that the present ppm reading and analog output signal are being held at either the last valid live CO value or an operator selected value (see TEST VALUE).

The flag displays under any of the following conditions:

(1) 2nd function HOLD key is depressed.

(2) Remote HOLD COMMAND is initiated.

(3) During two segments of the calibration cycle.

(4) System-disabling fault is detected by the diagnostics prqmxn:

3 Hue gas temperature (Diag. code #2)

b Radiometer temperature (Diag. code #3)

E Intensity too high (Diag. code #5)

d Communication failure (Diag. code #6)

e Intensity too low (Diag. code #7) (IfFNO6~256.)

f Receiver in align mode (Diag. code #13)

g Communication o.k., but not updating (Diag. code #14)

(h) Test Value. Indicates that the present ppm reading is a manually selected value which provides a desired analog output signal. Both reading and output signal are being held and the held output flag is displayed simultaneously.

The flag displays only when a TEST VALUE is manually entered from the keyboard (paragraph 3-4.a, STORE ENTRY key for keystroke sequence).

(c) PPM. Indicates that parameter displayed is expressed in units of parts-per-million,


(1) Reading live, held or test CO value.

(2) Displaying full scale range.

(3) Displaying alarm setpoints and deadbands.

(d) ‘C, Meters. Indicates that temperature or optical path length presently displayed is expressed in the MKS unit system, degrees Celsius or meters, respectively.

(e) “F, Feet. Indicates that temperature or optical path length presently displayed is expressed in the FPS unit system, degrees Farenheit or feet, respectively.

2. Control Module Display - Lower Display. This is a 3-l/2 digit liquid crystal display (LCD) which indicates the two-digit function code corresponding to the analyzer function currently accessed. Mnemonics may also appear in this display in selected functions.

Display Flags:

(a) CAL Cycle. Indicates either that the calibration cycle is in progress (steady flag) or that the SET ZERO function is active (flashing flag).


(1) Calibration cycle is automatically initiated by the microprocessor.

(2) Calibration is manually initiated from the keyboard by depressing the 2nd function CALJOFF key.

(3) Primary zero calibration is initiated from the keyboard by depressing the 2nd function SET ZERO key.

NOTE

Flag flashes under this condition.

(b) MAN Gas T. Indicates that flue gas temperature value used by the microprocessor to corn- pute temperature-compensated CO concentration values is manually selected; the flue gas temperature probe is not being used.

IB-1MSlOA 3.11

(c) Fault. Indicates that microprocessor diagnostics program has detected one or more fault/error conditions in the system The flag is accompanied by the HELD/OUTPUT flag if the detected fault is system-disabling; and, until acknowledged or unless disabled, by:

(1) The control module audible alarm

(2) Alarm3

The flag will display until such time as the fault/error condition has been corrected (Section 7, Troubleshooting).

(d) Alarm 1. Indicates that measures CO concentration value has:

Exceeded setpoint value if alarm 1 has been programmed as a high alarm;

OR

Fallen below setpoint value if alarm 1 has been programmed as a low alarm.

The flag displays:

In conjunction with ALARM 1 triac turning on.

Until measured CO concentration value has returned to within setpoint and deadband (paragraph 3-4.n, for explanation of deadband).

(e) Alarm 2. Indicates that measured CO concentration value has:

Exceeded setpoint value if alarm 2 has been programmed as a high alarm;

OR

Fallen below setpoint value if alarm 2 has been programmed as a low alarm.

The flag displays:

In conjunction with alarm 2 triac turning on.

Until measured CO concentration value has returned to within setpoint and deadband (paragraph 3-4.n. for explanation of deadband).

When either alarm 1 or alarm 2 is active, alarm 3 and the audible alarm will, unless disabled, be activated also and remain so until the condition is acknowledged. The alarm 1 and alarm 2 flags and triacs are not deactivated by the acknowledgment -- only alarm 3 and the audible alarm.

(t) Disabled. Indicates that alarm 1 triac, alarm 2 triac, alarm 3 relay and control module audible alarm are disabled.

NOTE

Hags for alarm 1, alarm 2 and fault remain operational.

The flag displays only when the 2nd function ENABLE/OFF key is depressed to toggle from the ENABLE state to the OFF state.

IB-lC6-51OA 3.12

3. Audible Alarm. The audible alarm is designed to provide a locally audible alert to an acknowledged fault/error condition or a CO concentration alann (ALARM 1 or ALARM 2). The alarm buzzer is located directly behind the keyboard/display.

(a) The audible alwm may be silenced in either of two ways:

(1) Until the next occurrence, by depressing the ACK ALARM key

(2) Permanently, by using the 2nd function ENABLE/OFF key.

(3) Reset Alarm Setpoint to higher value.

(b) The audible alarm buzzer sewes the further function of providing audible feedback of the validity of keystroke entries:

(1) A single, short beep acknowledges a correct keystroke entry;

(2) A single, long beep indicates non-acceptance of an attempted incorrect keystroke entry.

4. Keyboard. The keyboard, Figure 3-11, provides the operator with a convenient means to access functions and initiate commands. Depending upon the function selected, access may entail a request to read data only; display and set or change a particular operating parameter or computational constant: or command an action. With the exception of certain commands which may be initiated directly from the keyboard, all functions are assigned two-digit function codes. A function may be accessed by entering the two digits of the function code from the keyboard. A complete listing of functions, function codes and function descriptions may be found in paragraph 3.6.

Figure 3-11. Control Module Keyboard

To provide analyzer interface in a manner as user-friendly and convenient as possible, those time- tions and commands requiring access on a routine basis are identified directly on the keyboard. These are termed “secondary” or “2nd” functions and may be accessed directly, without the need to enter the two-digit function code. Full descriptions of the keyboard and secondary functions follow in paragraph 3-4.

Recognizing that access to many functions provides to opportunity to interrupt normal analyzer operation and alter operational parameters or computational constants, thus affecting calibration and/or analog output signal, freedom of access to such functions should be limited. The system provides two levels of security protection for this purpose. For each level of security, a code is required to access the protected functions. In the following function descriptions, the terms “user locked” and “factory locked”, and the associated “usercode” and “factory code”, refer to the two levels of security protected functions. A listing of user and factory locked functions, as well as instructions for implementing the security systems may be found in paragraphs 3-6 and 3-7.

3-4. KEYBOARD FUNCTIONS. The following is a description of the primary and secondary functions associated with each of the 16 keys on the keyboard. Primary function of the key as printed on the lower portion of key in bold print. Secondary function refers to the analyzer function as printed on the upper portion of the key against the orange background. Access to a secondary function requires depressing the 2nd KEY key, causing the mnemonic 2nd Fn to appear in the display. The desired secondary fonction key is then depressed. If the desired secondary function is one which displays data, the data appears in the upper display and the function code appears in the lower display. Changing data in this type of function, accessing other types of functions and fully entering user locked functions require keystroke sequences described below. In the descriptions it is assumed that each function is being accessed on a locked system. The step of storing the user code can be omitted if:

The user code has been set to 0.

There has been keyboard activity with no lapse of more than 5 minutes since last entering the code.

See paragraph 3-7 for a more complete description of the security system.

a. STORE ENTRY Key.

1. Primary function.

(a) Enters data into the system. Data pending storage into the system will flash in the upper display. Depressing the STORE ENTRY key will enter the data and cause it to appear steady in the display.

(b) Initiates certain command functions.

(c) Enters test Value. The STORE ENTRY key can be used directly, whenever the system is in its default mode (reading CO in ppm), to set the display and corresponding analog output to a user-selected test value. This is particularly useful for calibrating a chart recorder or any other equipment using the analog outputs. It may also be used to test ALARMS 1 and 2.

A test value, YYYY, may be entered by using the following keystroke sequence:

In-10651oA 3.14

(1)

KEYSTROKE

KOl

DISPLAY UPPER LOWER

XxXx co (chrrent Live ppm)

(2)

(3)

[STORE ENTRY] CODE

11t1t1t1 User Code (Flashes)

User Code

USE

USE

(4) [STORE ENTRY] 0 (Flashes)

00

(5) MMMM m (Flashes)

00

(6) [STORE ENTRY] YYYY (Steady)

co

FLAG

PPM

PPM HELD OUTPUT TEST VALUE

Additional test values can be entered by repeating Steps (4) thro (6) or, after more than 5 minutes with no keyboard activity, by repeating Steps (2) thro (6).

To leave the test value mode, use the 2nd function hold/off to remove the held/output as described in paragraph 3-4.i

2. Secondary Function. -- None.

b. J*l Decimal PoinURESP TIME Key.

1. Primary Function. Input decimal point into display/system. This is used in path length (FN24) only.

2. Secondary Function, Output Filter (FN25). This function allows the user to view/adjust the time constant of the analyzer from 0 to 255 seconds.

NOTE

This is additive to the analyzer’s inherent delay time of 5 seconds.

Example: Desired time constant = 10 seconds Delay time = 5 seconds Required RESP TIME entry - 5 seconds

NOTE

Response time is the time required Par the output to change from an initial value to a specified percentage of the final steady-state value of an input change. Response time to 95% is three time constants. In the example above, response time is 5 seconds (delay time) plus 15 seconds (three time constants), or 20 seconds to reach 95% of input change.

RFSP Time is a user locked function. The current time constant, XXX, may be displayed using the following keystroke sequence:

KEYSTROKE DISPLAY FLAG UPPER LOWER

(1) [Znd KEY] 2nd Fn

(2) t=p =I xxx (Set) 25 (Function Code)

Adjustment of the time constant requires entry of the user code and the following additional keystrokes:

(3) [STORE ENTRY] CODE USE

(4) [l[l[l[l User Code USE (Flashes)

User Code

(5) [STORE ENTRY] 0 (Flashes) 25

(‘3 MMM YYY(Flashes) 25

(7) [STORE ENTRY] YYY(Steady) 25

.Where YYY is the desired time constant io seconds.

c O/GAS TEMP Key.

1. Primruy Function. Input integer “0” into display/system.

2. Secondary Function, Gas Temperature (FNO2). This function allows the user to display the flue gas temperature as measured by the flue gas temperature probe. (See Section 3-6 for manual gas temperature procedures.)

The flue gas temperature, XXX may be displayed using the following keystroke sequence:

(1)

(2)


[2nd KEY] 2nd FII

[GAS TEMP] XXX 02 OC or OF (Function Code)

The displayed temperature will be that measured by the flue gas temperature probe even if the system is using a manually set value.

d. COICE Key,

1. Primary function. Clear or exit any function and place the system in default mode (reading CO in ppd.

NOTE

Clearing or aborting command functions which are toggled on and off, e.g. HOLD/OFF, require procedures described Par the particular functions.

2. Secondary Function, Clear Entry. This function allows the user to delete an accidental data entry (if noticed before depressing STORE ENTRY key) within a given function. To correct an accidental entry, depress [2nd KEY], [CE], [STORE ENTRY] and enter correct data. An automatic CE will also occur if more than four digits are entered into the display.

e. UCALIOFF Key.

1. Primary Function. Input integer “1” into display/system.

2. Secondary Function, Calibration/Off. This function allows the user to manually initiate a calibration cycle. It also allows the user to abort either a manually or automatically initiated calibration cycle (see paragraph 3-8, System Calibration, for detailed description and sequence of calibration cycle). CAL/OFF is a user locker function. A calibration cycle may be manually initiated using the following keystroke sequence:

(1)

(2)

(3)

KEYSTROKE

[2nd KEY]

K~OFFI

[1[111~1

User Code

DISPLAY FLAG UPPER LOWER

2nd Fn

CODE USE

User Code USE (Flashes)

(4) [STO= Emyl Eepnl, CO

CO)

CAL CYCLE HELD OUTPUT

IB-10651OA 3-17

The calibration cycle now proceeds as described in paragraph 3-8. To abort either a manually or automatically initiated calibration cycle, the same keystroke is used. Upon depressing the STORE ENTRY key, the calibration cycle is aborted. The CAL CYCLE flag clears, but, if the output was held, it will remain held (and the HELD OUTPUT flag displays) at current CO reading for an additional 30 seconds, after which the system returns to the default mode, reading CO in ppm.

A manual calibration cycle cannot be initiated while a SET ZERO calibration is in progress.

f. 2lSET ZERO Key.

1. Primary Function. Input integer “2” into displays/system.

2. Secondary function, Set Zero. This function allows the user to initiate a zero calibration cycle using the primary IR source. The primary IR source zero factor is computed and this factor is used to compute the system operating zero factor, and as a constant in updating the system operating zero factor in the calibration cycle described in paragraph 3-8, System Calibration. The zero calibration cycle will force the system to read zero ppm CO and will drive the analog signal output to the equivalent of zero ppm CO, regardless of the actual CO concentration in the flue gas. Therefore, the zero calibration cycle should be initiated only under the condition of a zero ppm flue gas CO concentration. This condition may be created by increasing the excess air (air/flue ratio) to a level sufficiently high to preclude the formation of CO. Often, the CO level cannot be entirely eliminated. Therefore, the only way to assure a 0 ppm level of CO is to use a portable combustion analyzer to measure for the presence of CO in the flue. If CO cannot be entirely eliminated, do not proceed with second key Set Zero. In this case, function 57 can be manually manipulated to adjust the reading of the Model 5100 CO Analyzer to agree with the portable combustion analyzer reading at near 0 ppm CO.

NOTE

A valid zero calibration cycle cannot be performed unless the boiler is operational and gen- erating combustion flue gases.

Refer to paragraph 3-8, System Calibration, for detailed description and sequence of the zero calibration cycle.

SET ZERO is a user locked function. The zero calibration cycle may be initiated using the following keystroke sequence:

KEYSTROKE

(1)

(2)

(3)

(4)

[2nd KEY]

[SET ZERO]

[l[l[lrl

User Code

[STORE ENTRY]

DISPLAY UPPER LOWER

2nd Fn

CODE USE


xxx (ppm)

co

FLAG

CAL CYCLE (Flashes)

IBllE-510A 3.18

Upon depressing the STORE ENTRY key, the zero calibration cycle begins and proceeds as described in paragraph 3-8 for a period of two minutes, during which a live ppm CO reading is displayed. When the two-minute period has elapsed, the CAL CYCLE flag is cleared and “Sto?” will appear in the upper display, requesting the user to accept the newly computed zero factor. Upon depressing the STORE ENTRY key, the factor is entered, the display reads zero ppm CO and the analog signal output goes to the equivalent of zero ppm co.

If the user chooses not to accept the newly-computed zero factor when “Sto?” appears, the CO key may be depressed and the system is placed in the default mode with no change. The user can choose to abort the zero calibration cycle during the two minutes prior to the appearance of “Sto?” by pressing the 2nd KEY and SET ZERO keys sequentially.

SET ZERO cannot be initiated while a calibration cycle is in progress.

g. 3iRANGE Key.


2. Secondary function, Select Full Scale Range (FN21). This function allows the user to view/adjust the full scale operating range, in ppm CO, to which the analog output is automatically scaled. The full scale operating range is selectable from 200 to 9999 ppm. For a given application, the maximum foil scale operating range is a timction of optical path length. The product of the full scale concentration and the optical path length may not exceed 33,000 ppm-ft. (10,000 ppm-m).

Example: Optical path length = 20 feet Maximum full scale operating range = 33,000 ppm. ft.= 1,650 20 ft.

NOTE

Minimum and maximmu limits of foil scale operating range are defined to assure valid readings and analyzer performance to specitications. Although these limits are not enforced by the analyzer software, they must be adherred to by the operator.

The analyzer can accommodate high full scale operating ranges in certain applications in- volving operation at elevated flue gas temperatures. Please consult Rosemount Analytical, Inc for applications engineering assistance.

RANGE is a user locked function. The full scale operation range, XXXX, may be displayed using the following keystroke sequence:

IElM-510A 349


(1)

(2)

[2nd KEYI

[RANGE1

2nd

XxXx @pm)

Fn

21 (FullCtiOll

Code).

PPM

Adjustment of the full scale operating range requires entry of the user code and the following additional keystrokes:

(3) [STORE ENTRY]

(4) [ltl[l[l

User Code

(3 [STORE ENTRY

(6) MMMM

(7) [STORE ENTRY]

CODE

User Code (Flashes)

USE

USE

0 (Flashes)

21

YYYY (Flashes)

21

YYY (Steady)

21

Where YYYY is the desired full scale range.

h. 2nd KEYiNEXT Key.

PPM

Primary Function. Allows the user to access to secondary, o12nd, functions without the need to utilize two digit function codes. The 2nd KEY and all secondary functions are color-coded orange on the keyboard. Depressing the 2nd KEY causes “2nd Fn” to appear in the display. Whenever these words appear in the display, one has direct access to any of the 15 functions shown in the upper half keys (Figure 3-9). The STORE ENTRY key is inoperative when “2nd Fn” appears in the display.

Secondary Function, Next. This function allows the user to access functions sequentially in order of function code, eliminating the need to enter the two-digit function codes.

E&ample: To proceed from FNOl to FN02 and on to FN03, use the following keystroke sequence:

KEYSTROIOZ DISPLAY FLAG UPPER LOWER

(1) [2nd KEyI 2nd Fn

(2) WW YYY 02

(3) [2nd KEY] 2nd Fn

(4) [NEm zzz 03

Where Xxx, YYY and ZZZ are the values of the corresponding functions.

Function codes are in numeric order from 00 to 99. Functions are further structured in smaller groups in logical order of use and these are listed in paragraph 3-6. Included in this I listing are spare function codes not presently used. When using the NEXT function to proceed sequentially through functions, if a spare function code is encountered, the system returns to the default mode, FNOO (CO).

i. 4RIOLDIOFF Key.


2. Secondary Function, Hold/Off. This function allows the user to hold the current live ppm CO value in the display and hold the analog output signal at the corresponding value. When in the held output mode, the toggle off function reverts the system to the default mode, live ppm CO/output.

HOLD/OFF is a user locked function. To hold the current live ppm CO value in the display and hold the analog output signal at the corresponding value, use the following keystroke sequence:

KEYSTROKE

(1)

(2)

(3)

(4)

[2nd KEY]

BIOLD/OFF]

[1[1[111

User Code

[STORE ENTRY]

DISPLAY UPPER LOWER

2nd

CODE

User Code (Flashes)

Fn

USE

USE

Xxx (mm) (Current CO)

co

EL&G

HELD OUTPUT

To toggle off the HOLD/OFF function, repeat keystroke sequence (l), (2), (3), and (4). When the STORE ENTRY key is depressed, the HELD/OUTPUT (and TEST VALUE) flag is cleared and the system is placed in the default mode, reading CO in ppm.

NOTE

The system wiU also be placed in the held output mode and display the held output flag upon remote hold command when a system-disabling fault is detected by the diagnostics program, and in 2 parts of the calibration cycle. Under these conditions, the toggle OFF function can remove only the user requested portion of the hold. If these other conditions are present, the output will remain held until they have been cleared. See paragraphs 3-&b, and 7-1, for descriptions of hold command and system-disabling faults, respectively.

j. S/SAVE n Key.


2. Secondary Function, Save n (FN38). This function albxvs the user to store in the system memory up to five sets of selectable system operating parameters, e.g., alarm s&points, time constant, calibration cycle frequency, etc. Parameters which are saved in each set include user locked functions (20 through 36) and factory locked functions 53 and 57. All other functions are common to each set.

The purpose of this function is to provide a convenient means for the user to detine and store several sets of operating parameters corresponding to different boiler operating conditions, e.g., steady vs. varying load, fuel type, soot blowing, etc. For a given condition of boiler operation, the analyzer is thus programmed for optimum operation.

NOTE

The current operating parameters are always automaticaUy kept in a power-fail protected mode in the system’s EEPROM. The Save n feature need be used only to save additional sets for later recall.

A set of operating parameters is identified by an integer n. Sets n = 1,2,3 and 4 are user locked. The following instructions pertain to saving operating parameters in system memory. Refer to paragraph 3-4.k, WRJZSTORE n Key, for instructions pertaining to the retrieval of stored sets.

To save the current set of operating parameters under the designator n = 1,2,3 or 4, use the following keystroke sequence:

KEXSTROKJI

(1)

(2)

(3)

(4)

(5)

(6)

[2nd KEyI

[SAVE n]

[STORE ENTRY]

t1t1t111

User Code

[STORE ENTRY]

In1 (l-4)

(7) [STORE ENTRY

DISPLAY UPPER LOWER

2nd Fn

n (l-5) 38 (Function (Displays last Code

CODE USE


0 (Flashes)

n (l-4) (Flashes)

38

38 (Where n= desired desig nator for ml.- rent save)

xxx @pm) (Current CO)

co

FLAG

Upon depressing [STORE ENTRY], keystroke (7), the contents of the operating registers (i.e., the present operating parameters) are saved in the set n. Additional sets may be saved by successive selections of operating parameters, with each set of selections followed by the keystroke sequence (1) through (7) above, up to four sets. The operating parameters, and the corresponding boiler operating condition, for each set should be recorded for use in quickly restoring the proper set when necessary. Table 3-1, provides a convenient format for recording this information.

The n = 5 set of operating parameters is factory locked. This is a precautionary measure to assure that, regardless of parameter changes in user locked sets 1 through 4, one set of recorded parameters is maintained under a high level of security, accessible for change only by those authorized with the factory code. To save a set of operating parameters into n = 5, use the following keystroke sequence:

EL10641OA 3-W

Table 3-1. System Operating Parameters/Boiler Operating Conditions Log Sheet

BOILER OPERATING CONDITIONS

PARAMETER SET n = 1 2 3 4 5

FUNCTION (FN)

RANGE (21)

ALARM 1 SETPOINT (31)

ALARM 1 DEADBAND (32)

ALARM 1 HIGH/LOW (32)

ALARM 2 SETPOINT (34)

ALARM 2 DEADBAND (35)

ALARM 2 HIGHlL.OW (36)

RESPONSE TIME (25)

AUTO CAL HOURS (20)

PROGRAM USER KEY (28)

SET GAS TEMP (27)

USER (SET ZERO) ZERO FACTOR

INITIAL SPAN FACTOR (53)

OUTPUT MODE (22)

SYSTEM UNITS (23)

PATH LENGTH (24)

INPUT FILTER (26)

CAL CELL (29)

USER CODE (30)

KEYSTROKE

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

[2nd KEY]

[SAVE n]

[STORE ENTRY]

[111[1[1

User Code

[STORE ENTRY

151

[STORE ENTRY

[1[11111

User Code

[STORE ENTRY]

Bl

[STORE ENTRY]

DISPLAY UPPER LOWER

2nd

n (l-5) (Last n saved or restored

CODE

User Code. (Flashes)

0 (Flashes)

5 (Flashes)

CODE

Factory Code (Flashes)

0 (Flashes)

5 (Flashes)

xxx @pm) (current CO)

Fll

38 (Function Code

USE

USE

38

38

FAC

FAC

38

38

co

FLAG

Upon depressing [STORE ENTRY], keystroke (ll), the contents of the operating registers (i.e., the present operating parameters) are saved in set n = 5.

k 6lRESTORE n Key.


2. Secondary Function, Restore n (FN39). This function allows the user to recall from system memory a set (n) of selectable system operating parameters and instantaneously input the set into the operating registers:Please refer to paragraph 3-4.j, S/SAVE n Key, for instructions pertaining to storing sets of operating parameters.

To restore a set of operating parameters, n = 1, 2,3, 4 or 5, use the following keystroke sequence:

KEYSTROKE

(1) [2nd KEYI

(2) [RESTORE n]

(3)

(4)

(5)

(6)

[STORE ENTRY

[1[1[1[1

User Code

[STORE ENTRY]

bl u-9

(7) [STORE ENTRY

DISPLAY UPPER LOWER

2nd Fn

n (l-5) 39 (Function (Last n saved Code or restored

CODE

User Code (Flashes)

USE

USE

0 (Flashes)

n (l-5) (Flashes)

39

39

xxx (wm) (Current CO)

co

FLAG

Upon depressing [STORE ENTRY, keystroke (7), the selected set (n) of operating parameters is recalled from system memory and instantaneously input into the operating registers. The selection will be rejected if the requested set has never been saved into or if the data is otherwise unreadable. In that event, the display will stay in Fn 39 and show the n value for the last successful save or restore in the upper display.

During routine analyzer operation under a given set n operating parameters, any or all of these parameters may be individually changed. Although the operating registers contain the altered parameters, the set n remains unchanged unless, or until, the altered parameters are saved in the same set n per the procedures of paragraph 3-4.j. Accessing the SAVE n or RESTORE n secondary functions will always cause the last n either saved or restored to appear in the upper display.

NOTE

Initial access to the SAVE n or RESTORE n secondary functions after a power interruption/restoration will cause “0” to appear in the upper display.

1. USER KEY/PROGRAM Key.

1. Primary Function. Allows the user immediate access to a pre-selected function, identified by a two-digit function code, without the need to enter the function code. Like the 2nd KEY fonction, the USER KEY function provides an added measure of convenience to the user in accessing a function which is expected to be accessed on a regular basis. However, unlike secondary functions which are defined on the keyboard, the function accessed by the USER KEY function is pre-selected by the user. Pre-selection procedures are described below under secondary function-program.

IBlC6-SlOA 3.26

Depressing the USER KEY key will cause the pre-selected two-digit function code to appear in the lower display and the corresponding data to appear in the upper display.

2. Secondary Function, Program USER KEY (FN28). This function allows the user to select the function to be accessed by the USER KEY key.

PROGRAM is a user locked function. The currently programmed function may be displayed using the following keystroke sequence:

UEYSTROUE DISPLAY

I

FLAG UPPER LOWER

(1)

(2)

[2nd KEYI 2nd

[PROGRAM] Xx (FWlCtiOIl Code)

Fn

28

To program a new function to t tional keystrokes:

(3) [STORE ENTRY]

(4) [1[11111

User Code

(3 [STORE ENTRY]

(6) M M

(7) [STORE ENTRY]

m. ‘IAHAGNOSE Key.

R accessed by the USER KEY key, use the following addi-

CODE

User Code (Flashes)

USE

USE

0 (Flashes) 28

YY (Flashes) 28

YY (Steady) 28


2. Secondary Function, Diagnostics (FNl5). This function allows the user to display diagnostic code numbers corresponding to one or more system fault/error conditions detected by the diagnostics program.

When the FAULT flag is displayed, diagnostic code numbers may be displayed using the following keystroke sequence:

1&106-51OA 3.27

KEYSTROKE

(1) [2nd KEY]

(2) [DIAGNOSE]

DISPLAY UPPER LOWER

2nd

xx (1st Diagnostic Code No. displayed for 2 seconds)

w (2nd Diagnostic Code No. displayed for 2 seconds)

END (Displayed for 2 seconds)

xx (1st Diagnostic Code No. displayed steadily)

Fn

15 (Function Code)

15

15

15

FLAG

The display sequence indicated above is then automatically indexed, diagnostic response to a FAULT flag generated by two system fault/errors. Should all the existing fault conditions be corrected, the FAULT tlag will automatically clear and “End” will appear io the upper display.

Multiple Paultkrrors are displayed in numeric sequence and not necessarily in order of oe currence.

Refer to Section 7, for a more complete description of the diagnostics system, including diagnostic code numbers, associated fault/errors and diagnostics procedures.

n. S/ALARM 1 Key.


2. Secondary Function, Alarm 1 Setpoint (FN31). This function allows the user to view/adjust the setpoint of alarm 1 in ppm CO. The setpoint is adjustable from 0 to 9998 ppm. Entering a setpoint of 9999 ppm disables the alarm.

Alarm 1 is a user locked function. The alarm 1 setpoint may be displayed using the following keystroke sequence:

15106410A 3.28


(1) [2nd KEY

(2) [ALARM l]

2nd

xxx (current Setpoint)

Fll

31 (Function PPM Code

Adjustment of the alarm 1 setpoint requires the following additional keystroke%

(3) [STORE ENTRY

(4) [l[l[l[l

User Code

(5) [STORE ENTRY

(6) MMM (New Setpoint)

(7) [STORE ENTRYj

CODE

User Code (Flashes)

USE

USE

0 (Flashes)

YYY (Flashes)

YYY

31

31

31 PPM

Additional alarm 1 functions are deadband (FN32) and h&b/low selection (FN33). Since the three alarm 1 function codes are in numeric sequence, the user may proceed through them using the NEXT function.

The deadband is adjustable from 0 to 9999 ppm. The deadband may be adjusted to a suitable value to prevent repeated state changes of the alarm 1 triac as measured CO concentrations vary about the s&point.

Example: If alarm 1 is a high alarm with a setpoiot of 500 ppm, alarm 1 turns on when the measured CO concentration exceeds 500 ppm and turns off only when the concentration falls below 4.50 ppm CO.

Proceeding from setpoint selection above, the deadband may be displayed/adjusted using the following additional keystrokes:

(8 [2nd KEYI

(9) W‘=l

(10) [STORE ENTRY

(11) MMM (New Deadband)

(12) [STORE ENTRY]

2nd

xxx (Current deadband)

0 (Flashes)

YYY (Flashes)

Fn

32 (Function Code)

32

32

PPM

YYY (Steady)

32 PPM

Alarm 1 may be set as a high or low alarm. A high alarm is active whenever the ppm indicated in FNOO exceeds the setpoint. A low alarm is active whenever the indicated ppm is equal to or less than the setpoint. Proceeding from the keystroke sequences above, high/low selection is accomplished using the following additional keystrokes:

KEYSTROKE

(13) [2nd KEY

(14) wm

DISPLAY FLAG UPPER LOWER

2nd Fn

0 (or 1) 33 (Fonction Code)

NOTE: Displayed “0” indicates low alarm. Displayed “1” indicates high alarm.

(15) [STORE ENTRY]

(16) tOI or 111

(17) [STORE ENTRY

0 (Flashes)

0 or 1 (Flashes)

33

33

0 or 1 (Steady)

33

o. 9lALARM 2 Key.


2. Secondary Function -- Alarm 2 Setpoint (FN34). This function allows the user to view/adjust the setpoint of Alarm 2 in ppm CO. Display and adjustment procedures are identical to those described in paragraph 3-4.11 for alarm 1. Function codes are 34, 35 and 36 for setpoint, deadband, and high/low selection, respectively. Alarm 2 may be accessed in the same manner as described in paragraph 3-4.n for alarm 1, or the user may proceed directly from alarm 1 high/low selection (FN33) to alarm 2 s&point (FN34) using the NEXT function.

p. ACK ALARM/ENABLE/OFF Key.

1. Primary Function, Acknowledge Alarm. Depressing the ACK ALARM key silences the audible alarm and de-energizes the alarm 3 relay, until next occurrence. It does not torn off alarms 1, and 2 nor does it clear display flags alarm 1, alarm 2 or fault (and held output if system-disabling fault). Alarms 1 and 2 are turned off only when the alarm conditions are corrected or when they are disabled through the ENABLE/OFF function described below. Display flags are cleared only when the fault/error and alarm conditions are corrected.

The ACK ALARM key may be pressed at any time to acknowledge an alarm except when the words “2nd Fn” appear in the display. Io this case, pressing the key will perform the secondary function described below.

2. Secondary Function, ENABLE/OFF. This function allows the user to enable or disable the alarm 1 triac, alarm 2 triac, alarm 3 relay and audible alarm. Display flags alarm 1, alarm 2 and fault (and held output if system-disabling fault) remain operational in [he OFF, or disabled, state of this function.

IB-lK-SIOA 3.30

ENABLE/OFF is a user locked function. The user may toggle from the ENABLE to the OFF, or disabled, state using the following keystroke sequence:

KEYSTROKE

(1)

(2)

(3)

(4)

[2nd KEYI

[ENABLE/OFF]

[l[l[l[l

User Code

[STORE ENTRY]

DISPLAY UPPER LOWER

2nd Fn

CODE USE


xxx @pm) co

PIAG

DISABLED I

To toggle from the OFF state to the ENABLE state, use the same keystroke sequence (1) through (4). Upon depressing [STORE ENTRYJ, the state change is accomplished and the DIS- ABLED flag clears.

3-5. CO COMPUTATION. The absorption of infrared radiant energy by molecules of carbon monoxide is a phenomenon whose characteristics are theoretically predictable. The absorption coefficient for carbon monoxide is constant at a specific wavelength under conditions of constant temperature and pressure. If any, or a combination, of these conditions (wavelength, temperature, pressure) changes, the absorption coefficient changes. When applying the principles of infrared absorption spectroscopy to the measurement of carbon monoxide in combustion flue gases, variations in temperature and, to a lesser extent, pressure must be expected. The absorption characteristics of carbon monoxide, then, are also expected to vary. Considering the dynamics of the combustion process, variations in carbon monoxide concentration can be expected to occur simultaneously with the variations in molecular absorption characteristics. To obtain a reliable measurement of concentration, therefore, it is necessary to compensate, or correct, the basic measurement for errors due to temperature-induced variations in absorption characteristics.

Variations in flue gas temperature also cause variations in gas density. Densities of all flue gas constituents vary equally and the volume concentration of carbon monoxide remains the same; however, since the computed carbon monoxide concentration value is based upon the number of carbon monoxide molecules encountered by the infrared radiant energy, and this number does vary with density, the gas temperature/density fluctuations must be accounted for in the carbon monoxide computation.

The carbon monoxide computation considers finally the characteristics of the detection system, or radiometer assembly, itself. The high degree of specificity to carbon monoxide is achieved through gas filter correlation and the narrow bandpass optical filter. The bandpass filter is placed on the pyroelectric detector and allows the detector to respond only to a very narrow waveband of radiant energy. The width of this band remains constant; however, its position in the spectrum varies with the ambient temperature around the bandpass filter. To compensate for variations in absorption coefficient with spectral position, the detector is properly characterized over the full ambient temperature range to which the analyzer will be subjected. This characterization is incorporated into the carbon monoxide computation.

The relationship between measured carbon monoxide concentration and the factors discussed above may be expressed as follows:

CO Oc Absorption Factor * Gas Temp Factor Optical Path Length

lB-l(MslOA 3.31

CO concentration values are computed by the microprocessor using the following equation:

co @pm) = 2 * FN54 * f(x) /f(y) FN24

Where: x=5*1--

[

FN5* * f(z) * - FNOS Absorption Factor

213 1 FN04

y = mo2 cc, ‘73 Gas Temp Factor 296

z = FN03(%) -30 Detector Temp Factor

50

FN54 = System Operating Span Factor FN24 = Optical Path Length (Meters) FN58 = System Operating Zero Factor FN05 = Nitrogen Cell Intensity (O-8191) FNO4 = CO Cell Intensity (O-8191) FN02 = Flue Gas Temperature (“C) FN03 = Radiometer Temperature (“C)

@) = z. + ZIZ + zz2 + z32 + z4z4 + z52 + z,z” 2”

Where: X, Terms are output linearizer coefficients;

Y,, Terms are gas temperature compensation coefficients;

Z,, Terms are ambient temperature coefficients for detector.

3-6. FUNCTION LISTING AND DESCRIPTION. The following is a listing and description of all analyzer functions by two-digit function code. Any function may be accessed by entering the two-digit function code from the keyboard. Beyond display of data in a given function, access is limited by the function security system. This system is described in paragraph 3-7, and the level of security (user locked or factory locked) assigned each function may be found in Table 3-2.

The keystrokes required for data entry into any of these functions follow the pattern described in paragraph 3-4. While the current value is being displayed, press STORE ENTRY. If a security code is requested, enter that and press STORE ENTRY again. If it is a command function, the action will be executed. If it is a data entry function, a flashing “0” will be displayed. Enter the desired data (which will flash in the upper display pending acceptance), then press STORE ENTRY a final time. Steady display of the desired data indicates successful entry.

IElM-510A 3.32

FUNCTION CODE ml DESCRIPTION

00 (CO)

01

02

03

04

0.5

06

07

08

09

10

11

12-14

Default Mode -- Reading CO in ppm, subject to the filters imposed in FNZS and FN26.

Source Temperature -- Displays the temperature of the IR source radiating surface in degrees Celsius or Farenheit, as selected by the user in FN23. This temperature is not updated during the held portions of the calibration cycle.

Gas Temperature -- Same as 2nd GAS TEMP function (paragraph 3-4.c.). This temperature is not updated during the held portions of the calibration cycle.

Radiometer Temperature -- Displays the temperature inside the detector tube in degrees Celsius or Farenheit, as selected by the user in FN23. This temperature is not updated during the held portions of the calibration cycle.

Read CO Cell Intensity -- Displays the intensity (O-8191) of the infrared radiation from the primary source as measured through the CO correlation gas cell. This signal is filtered by the time constant in FN26. Use FNO6 during HELD OUTPUT segments of the calibration cycle.

Read Nitrogen Cell Intensity -- Displays the intensity (O-8191) of the infrared radiation from the primary source as measured through the nitrogen gas cell. This signal is filtered by the time constant in FN26. Use FN07 during HELD OUTPUT segments of the calibration cycle.

Read Last CO Cell Intensity -- Displays the intensity (O-8191) of the infrared radiation from the primary or calibration source as last measured through the CO correlation cell. FN06 may be used during held output segments of the calibration cycle, i.e., when the calibration soume is in the optical path.

Read Last Nitrogen Cell Intensity -- Displays the intensity (O-8191) of the infrared radiation from the primary or calibration source as last measured through the nitrogen cell. FN07 may be used during held output segments of the calibration cycle, i.e., when the calibration source is in the optical path.

Read CO (Current Value) -- Displays currently computed ppm CO concentration value while the output is being held at the last live ppm CO value or at a test value. The displayed value is not filtered, i.e., the input and output filters (RN26 and 25) are not operational during a held output mode. FN08 is not operational during the held output segments of the calibration cycle. When the output is not held, IN08 is identical to FNOO.

Display Test -- Displays all segments and flags of both upper and lower displays.

Cold Junction Temperature -- Displays the temperature inside the receiver module near ‘I?32 (Figure 2-7) in degrees Celsius or Farenheit, as selected by the user in FN23. Used in computing the thermocouple temperatures displayed in F’N’s 01 and 02, and in determining FauIt/Error No’s 2 and 4. This temperature is not updated during the held portions of the calibration cycle.

Ratio -- Displays FNO4/FNO5 x 10,000. Subject to filter imposed in FN26.

State 0 Spare -- Functions 12,13 and 14 are not currently used. Accessing any of these functions causes the system to revert to the default mode, reading CO in ppm.

IBl%-510A 3.33

FUNCTION CODE m DESCRIPTION

15 Diagnostics -- Same as 2nd diagnose function (paragraph 3-4.m.).

16,17 State 0 Spare -- Functions 16 and 17 are not currently used. Accessing either of these functions causes the system to revert to the default mode, reading CO in ppm.

18 Hours -- Displays the time elapsed, in hours, since the microprocessor clock has been reset. Displays 0 to 255. The clock is reset at the start of each automatic calibration cycle, upon power interruption/restoration, or by changing value of FN20.

19

20

Minutes -- Displays the time, in minutes, of the hour displayed in FNl8.

Auto Cal Hours (O-255) -- This function allows the user to view/adjust the frequency of the automatic calibration cycle from once per hour to once per 255 hours. An entry of 0 prevents the automatic initiation of a calibration cycle. Any change to the stored value resets the hours and minutes clock displayed in FN’s 18 and 19.

21

22

Select Full-Scale -- Same as 2nd range function (paragraph 3-4.g.).

Output Mode -- This function allows the user to select which one of the four isolated analog output signals is available at the rear terminals of the control module.

Display/Select “0” Display/Select “1”

NOTE

O-20mADC or OdVDC 4-2OmADC or 1-SVDC

Selecting “0” or “1” allows the operator to make available the corresponding voltage and current outputs; but only one of these may be used at a time. Voltage and current may not be used shnultaneously unless the voltage load is greater than 20kohms.

23 System Units -- This function allows the user to select the FPS unit system (degrees Farenheit, feet) or the MKS unit system (degrees Celsius, meters) for:

Display of -- Source Temperature (FNOl) Gas Temperature (FN02) Radiometer Temperature (FNO3) Cold Junction Temperature (FNlO)

Display/Adjustment of -- Optical Path Length (FN24) Manual Gas Temperature (FN27) Display/Select “0’ MKS Unit System Display/Select “1” FPS Unit System

24 Path Length -- This function allows the user to set the optical path length from 1.5 to 40 feet or 0.46 to 12.2 meters. The optical path length is the distance from the IR receiver. The path length may be set with a resolution of 0.01 foot or meter.

25 Output Filter (O-255 sec.) -- Same as 2nd rasp time function (paragraph 3-4.b). (Apical value is set at 10 seconds.)

ILLlL?6-SIOA 3-34

FUNCTION CODE (FN)

26

27

28 Program -- Same as 2nd program user key function (paragraph 3-4.1.).

29 Cal Cell -- This function allows the user to insert the calibration gas cell into the optical path Entry of “1” into the function will insert the cell and entry of “0” will remove the cell from the optical path

DESCRIPTION

Input Filter (O-255 sec.) -- This function allows the user to impose a time constant on the CO and nitrogen cell intensity signals prior to the computation of CO in ppm. It is useful when reading intensities in FN04 and FRO5 and the ratio in FN’s 11 and 61. During normal analyzer operation, this function is set to zero, unless additional filter- ing is required beyond the limits of the output filter.

Set Gas Tern -- This function allows the user to select automatic or manual flue gas temperature compensation and, if manual, to select the value used by the microprocessor to compute temperature compensated CO concentration values.

Automatic temperature compensation is selected by entering a “0” into the function. The flue gas temperature probe provides the data used by the microprocessor to compute temperature compensated CO concentration values. This is recommended for normal operation.

Manual temperature compensation is selected by entering the expected nominal flue gas temperature (“C or “F) into the function. Regardless of actual flue gas temperature fluctuations, the entered value will be used by the microprocessor. When manual temperature compensation is used, the MAN GAS T flag displays continuously.

Manual temperature compensation should normally be used only when the flue gas temperature probe is out of service.

NOTE

Data displayed during the time that the calibration cell is in the optical path must be corre- lated with parameters in other fonctions. FN29 is intended for specific troubleshooting procedures to be carried out by a Rosemount service representative.

During normal operation, FN29 is set to zero. Whenever FN29 is not zero, fault condition 9 will be displayed as a reminder.

30 User Code -- This function allows the user to display, change or bypass the user code. The analyzer is shipped from the factory with a user code of 5100. Entry of any one, two, three or four-digit number into the function will change the user code. Entry of “0” will bypass the user code feature. Please refer to Section 3-7, Function Security System, for further information regard- ing user locked functions and the user code.

31 Alarm 1 Setpoint -- Same as 2nd alarm 1 function (paragraph 3-4.n).

32 Alarm 1 Deadband -- This function is described in paragraph 3-4.n.

33 Alarm 1 High/Low Selection -- This function is described in paragraph 3-4.n.

34 Alarm 2 Setpoint -- Same as 2nd alarm 2 function (paragraph 3-4.0.).

FUNCTION CODE aw DESCRIPTION

35

36

37

38

39

40

41-49

50

51

52

53

Alarm 2 Deadband -- This function is described in paragraph 3-4.0.

Alarm 2 High/Low Selection -- This function is described in paragraph 3-4.0.

State 0 Spare -- Functions 37 is not currently used. Accessing this functions causes the system to revert to the default mode, reading CO in ppm.

Save n -- Same as 2nd sake n function (paragraph 3-4.j.)

Restore n -- Same as 2nd restore n function (paragraph 3-4.k).

Truncate Negative ppm -- The Model 5100, like any other measuring instrument, is subject to noise. If the tme reading should be 0 ppm, or a low value approaching 0 ppm, the measured ppm will vary between slightly positive and slightly negative values. If the 4-20 mADC (l-5 VDC) option has been selected in FN22, these “negative” ppm readings will generate an output of less then 4 mADC (or less than 1 VDC). This may be undesirable in certain control and data acquisition systems. FN40 provides a means to truncate the output at 0 ppm

Display/Select “0” Negative readings truncated at zero Display/Select “1” “Live”, non-truncated zero

The mode selected applies to both FNOO and F’NO8.

State 0 Spare -- Functions 41 through 49 are not currently used. Accessing any of these functions causes the system to revert to the default mode, reading CO in ppm.

Reference Voltage to A/D Converter (Millivolts) -- Displays the reference voltage against which analog signals input to the A/D converter are compared for accurate digital conversion by the IR receiver module CPU. Access for adjustment is factory locked. (See paragraph 8-22, Reference Voltage Adjustment.)

Initial (Factory) Span Factor, Internal Calibration Source -- Displays the span factor established at the factory using the internal calibration source and calibration gas cell. This factor is used with the factors in functions 52 and 53 to compute the system operating span factor (FN54). (See paragraph 3-8, System Calibration.) Access for adjustment is factory locked.

Calibration Cycle Span Factor, Internal Calibration Source -- Displays the span factor established in the last manually or automatically initiated calibration cycle. The factor is updated with each calibration cycle. This factor is used with the factors in timctions 51 and 53 to compute the system operating span factor (FN54). (See paragraph 3-8, System Calibration.) Access for adjustment is factory locked.

Initial (Factory) Span Factor, Primary Source -- Displays the span factor established at the factory using the primary source and an independent calibration standard. This fat. tor is used with the factors in functions 51 and 52 to compute the system operating span factor (FN54). (See paragraph 3-8, System Calibration.) Access for adjustment is factory locked.

ELlC!6-51OA 3.36

FUNCTION CODE m

54

5s

56

51

58

59

60

61

62-98

99

DESCRIPTION

System Operating Span Factor -- Displays the span factor used by the system to compute CO in ppm (see paragraph 3-S. CO Computation). This factor is computed using the factors in functions 51, 52 and 53 and is recomputed with each manually or automatically initiated calibration cycle. (See paragraph 3-8, System Calibration.) Ac- cess for adjustment is factory locked.

Initial (Factory) Zero Factor, Internal Calibration Source -- Displays the zero factor established at the factory using the internal calibration source. This factor is used with the factors in functions 56 and 57 to compute the system operating zero factor (FN.58). (See paragraph 3-8, System Calibration.) Access for adjustment is factory locked.

Calibration Cycle Zero Factor, Internal Calibration Source -- Displays the zero factor established in the last manually or automatically initiated calibration cycle. This factor is used with the factors io functions 55 and 57 to compute the system operating zero factor (FNS8). (See paragraph 3-8, System Calibration.) Access for adjustment is factory locked.

User (SET ZERO) Zero Factor, Primary Source -- Displays the zero factor established in the zero calibration cycle (SET ZERO) using the primary source. This factor is used with the factors in functions 56 and 57 to compute the system operating zero factor (FNS8). (See paragraph 3-8, System Calibration.) The value of FNS7 can be manually selected when CO cannot be eliminated from the floe gas.

System Operating Zero Factor -- Displays the zero calibration factor used by the system to compote CO in ppm (see paragraph 3-5, CO Computation). This factor is computed using the factors in functions 55, 56 and 57 and is recomputed with each manually or automatically initiated calibration cycle and with each zero calibration cycle (SET ZERO). (See paragraph 3-8, System Calibration.) Access for adjustment is factory locked.

State 0 Spare -- Function 59 is not currently used. Accessing this function causes the system to revert to the default mode, reading CO in ppm.

Peek/Poke -- This function allows the user to access all system memory registers. Within FN60, all memory addresses and all data contained in the registers are coded in the hexadecimal system. Access to alter data (POKE) is factory locked. Access should be limited to only a Rosemount service representative or the user’s designated service personnel, carefully following the instructions contained in paragraph 3-10.

Ratio -- Displays FNO4/FNOS x 10,000. Same as FN11.

State 0 Spare -- Functions 62 through 98 are not currently used. Accessing any of these functions causes the system to revert to the default mode, reading CO in ppm.

Re-Lock Keyboard -- This is a command function which will instantly re-lock user and factory code-protected functions as if the normal five-minute timeout had occurred. It can be used after data entry to insure against subsequent inadvertent changes to the operating parameters. FN99, is, itself, not locked and, after performing its action, automatically retmns the system to its default mode, reading CO in ppm.

IB-lO&SlOA 337

a.

b.

c”

Secondarv Functions. Analyzer functions are listed above by two-digit function code and, where applicable, corresponding secondary functions are noted with paragraph references for descriptions. Table 3-2, also provides a convenient cross-reference. Several secondary functions (command functions) are not assigned two-digit function codes. These are:

ENABLE/OFF HOLD/OFF CAL/OFF SET ZERO NEXT CE

All of these are folly described in paragraph 3-4.

Hold Command. The system may be placed in the held output mode and display the held output flag upon remote hold command. The hold command is issued by a switch (user supplied) connecting terminal 28 (hold command) to terminal 30 (common) at the rear of the control module. The hold command overrides the secondary HOLD/OFF function, i.e., the held output mode may not be toggled off from the keyboard.

Hold Flag. Through the duration of a held output mode, regardless of the cause for entering the mode, the system issues a logic “1” flag at terminal 29 (hold flag) at the rear of the control module. (NOTE: Logic level “1” is a 2.4 VDC minimum for standard TTL input. Logic level “0” is a 0.6 VDC maximum at 1.6 mADC maximum sink current.)

3-7. FUNCTION SECURPrY SYSTEM. Access to certain functions provides the opportunity to interropt normal analyzer operation and alter system operating parameters or computational constants. Such altera- tions can affect calibration, the CO computation and, ultimately, the validity of the analog output signal. Therefore, the system is designed to limit freedom of access to such functions. The limitations are imposed by two levels of security protection. For each level of security, a code is required to access the protected functions. Security protected functions are termed “user locked” or “factory locked” functions and the security systems are described below.

a. User Locked Function Secur@. The user locked function security system is designed to limit access to FNOO, functions 20 through 49, and all keyboard 2nd functions except diagnose, next, gas temp and CE. These user locked functions either contain system operating parameters or execute commands which interrupt normal analyzer operation. Full access to these functions can be limited, therefore, to the user(s) knowledgeable in the operation of the analyzer and authorizes with the user code.

NOTE

Data stored in a user locked function can always be displayed upon request; the function is locked onIy in terms of altering the data.

Access to a user locked function is accomplished as follows:

1. Depress [2nd KEYJ and the desired 2nd FUNCTION key or enter the desired two-digit function code.

2. If the desired function displays data to be altered, depress [STORE ENTRY]. The system re- quests the user code, displaying “CODE USE”.

(a) Enter the user code, which flashes in the upper display.

(b) Depress [STORE ENTRY]. The display flashes “O”, indicating acceptance of the user code and requesting entry of new data into the fimction.

(c) Depress [STORE ENTRY]. The data displays steady, indicating acceptance and storage of the data;

OR

3. If the desired function is a command function, “CODE USE” appears immediately:

(a) Enter the user code, which flashes in the upper display.

(b) Depress [STORE? ENTRY to execute the function. The lower display displays “CO” and the upper display displays CO in ppm, either live or held, depending upon the command function (see paragraph 3-4).

When the user code has been entered to access any user locked function, all user locked functions are unlocked and will remain so until such time as the user has initiated no keystrokes for a continuous period of five minutes, at which time the functions are locked once again. Storage to the user locked functions can also be re-locked at any time by accessing FN99.

The user code is stored in function 30. The analyzer is shipped from the factory with a user code of 5100. The code may be changed by accessing FN30 as described in Paragraphs 1 and 2 above and entering the new one, two, three or four-digit user code. To bypass the user code, allowing complete freedom of access to all user locked functions, the digit “0” is entered in FN30.

NOTE

It is strongly recommended that the user locked function security system be used. It is further recommended that the user code be given only to those personnel knowledgeable in, and responsible for, the proper operation of the analyzer. This will prevent inadvertent changes in the analyzer status and operating parameters.

b. Factorv Locked Function Securi@. The factory locked function security system is designed to limit access to functions 50 through 60. These functions allow access to all system EEPROM registers, including the calibration factors and factory-established constants. Adjustments to data in these fnnc- tions are not required during normal analyzer operation. When access to these functions is required, it should be made only by a Rosemount setvice representative or by the user% designated service personnel.

Alteration of data in functions 50 through 60 requires entry of the factory code, requested by the system as “CODE FAC”. The factory code is “2400”.

3-8. SYSTJSM CALIBRATION. The analyzer requires zero calibration upon commissioning and periodically thereafter, as described below. The zero calibration cycle establishes a zero factor using the primary source under the condition of zero ppm in the flue gas CO concentration. Routine calibration thereafter is performed by the analyzer’s integral automatic calibration system. A calibration cycle may be initiated automatically by the microprocessor at a user-selected frequency or manually from the keyboard. Zero and span corrections are made automatically. The following paragraphs describe the zero calibration cycle and the automatic calibration cycle.

I&106-51OA 339

a. Zero Calibration Cvcle. The zero calibration cycle causes the system to read zero ppm CO and drives the analog output signal to the equivalent of zero ppm CO. It does this by computing a new user zero factor (FN57), causing recomputation of the system operating zero factor (FN58) to a value which results in an absorption factor of zero in the CO computation.

The system operating zero factor is defined as follows:

Where: FN55 = Initial (factory) zero factor, internal calibration source

FN56 = Calibration cycle zero factor, internal calibration source

FN57 = User (SET ZERO) zero factor, primary source

FN58 = System operating zero factor

As defined previously in Section 3-5, CO @pm) is computed as follows:

Eq2CO@pln) = ,*FN54*f(x))‘f(y)

FN24

The absorption factor in the computation is f(x), where:

Eq.3x=s* I-

L

FN58 a ffif . Em5

213 1 FNo4

F!&.4f[x) = s+~x+~+~+x4x4+x+x6x6

To result io a computation of zero ppm in equation (2), corresponding to zero ppm in flue gas, the absorption factor f(x) must be zero. From equation (4). this requires that x must be zero (X,, is factory-set at zero).

Computing x = zero in equation (3), requires computation of the system operating zero factor as follows:

Eq.sFia = 2’3. r*FN04

f(z) FNo5

Where IWO4 and FNOS are the average intensities observed during the two-minute zero calibration and z is based on the current detector temperature.

Equation (3) becomes:

F%,.6r=S*l- 2’3 * f(z) * FNo4 * EN05

213 * f(z) * FN05 * FNO4

= 5 * [l - l]

= 0

(Eq,~FM6.FN57=213. 1 e l-%04 -- FM5 f(z) FNS6

f(z) FM6 FM6

FN57, User (SET ZERO) zero factor, primary source is computed in the zero calibration cycle, and using equation (l), FM8, the system operating zero factor is recomputed.

NOTE

During this calibration, FN55 and FN56 are held constant. FN55 is factory set. FN56 is updated in the automatic calibration cycle to be discussed in the folIowing section.

The zero calibration cycle is initiated by using the 2nd set zero function as described in paragraph 3-4.f. During the two-minute duration of the cycle, CO and nitrogen cell intensity values accumulate in system memory. When the two-minute period has elapsed, FN57 is computed and stored and FN58 is recomputed and stored per the equations above.

Zero calibration should be performed upon initial commissioning of the analyzer and periodically thereafter. Under continuous operation, it is recommended monthly. At times, when it is convenient to do so, such at boiler startup, it is good practice to perform a zero calibration.

Because the zero point may vary with the quantity of interfering gases, a zero calibration should be performed, and the User zero factor, FN57, stored in the system memory (see paragraph 3-4.j), for each condition of boiler operation (e.g., firing a different fuel) that would significantly alter the flue gas characteristics of carbon dioxide and water vapor content and opacity. If these conditions change regularly, it is not necessary to perform the calibration with each change, but only to restore the appropriate FNS7 (along with other system operating parameters, if applicable) from system memoxy (see paragraph 3-4.k).

b. Automatic Calibration Cvcle. Routine calibration is performed by the analyzer’s integral automatic calibration system. The system employs a calibration source and calibration gas cell in the receiver module to perform both zero and span calibrations. The calibration source acts as an alternate source of infrared radiation to the primary source, unaffected by changes in flue gas conditions. The receiver CPU controls the duty cycle of the calibration source heater to produce an intensity approximating that of the primary source. When inserted into the optical path, the calibration source blocks the radiation from the primary source, creating a CO-free optical path to the detector for zero calibration. The calibration gas cell contains 100% CO at atmospheric pressure. Since the internal path length of the cell is 0.39 in (lcm), this represents 33,000 ppm-ft (10,000 ppm-m) of CO. When inserted into the optical path between the calibration source and the detector, this cell provides a known concentration of CO for span calibration.

As described in the previous section, the system operating zero factor is defined as follows:

IB-lC&SlOA 3-41

Where: FN55 = Initial (factory factor), internal calibration source

FN56 = Calibration cycle zero factor, internal calibration source

FN57 = User (SET ZERO) zero factor, primary source

FN58 = System operating zero factor

FN56 is updated with each automatic calibration cycle. It is proportional to the (temperature compensated) CO/Nz intensity ratio observed with the internal calibration source. With FN5.5 constant and FN57 established in the zero calibration cycle (SET ZERO). FN58, the system operating zero factor, is recomputed with each automatic calibration cycle.

The system operating span factor is defined as follows:

Where: FN51 = Initial (factory) span factor, internal calibration source

FN52 = Calibration cycle span factor, internal calibration source

FN53 = Initial (factory) span factor, primary source

FN54 = System operating span factor

FN52 is updated with each automatic calibration cycle. It is proportional to the output from the internal calibration gas cell. With FN’s 51 and 53 constant, FN54, the system operating span factor, is recomputed with each automatic calibration cycle.

The automatic calibration cycle may be initiated either manually or automatically. Manual initiation from the keyboard is accomplished using the 2nd CAUOFF function and the procedure described in paragraph 3-4.e. The cycle is initiated automatically at the frequency selected by the user in FN20, Auto Cal Hours (O-255), with the following exceptions:

1. If a set zero (zero calibration) is in progress at the time an automatic calibration cycle would normally begin, the start of the sequence will be deferred until the set zero has been completed.

2. If the receiver module is temporarily unable to respond (e.g., due to fault No. 6 or 13), the calibration cycle request will remain pending until the receiver can respond.

3. If a manually initiated calibration cycle is in progress at the time an automatic one would normally be initiated, that manual cycle is taken fulhhiig the calibration requirement.

IB-lO&SlOA 3-n

NOTE

It is recommended that the system be programmed for calibration every 24 hours.

c. The following is a description of the sequence of events of the calibration cycle, beginning at time O:OO, initiation of the cycle.

NOTE

Automatic initiation of the calibration cycle or changing FN20, Auto Cal Hours, resets the microprocessor clock to 0:OO. Manual initiation does not reset the clock.

1. At time 0~00 minutes.

(a) The CAL cycle flag displays and will continue to display throughout the calibration cycle.

(b) The held output flag displays. The output is held at the last live CO value.

(c) The hold flag appears across terminals JlO-2 and JlO-3 on the control module’s rezu terminal board.

(d) A solenoid positions the unheated calibration source in the optical path. This provides a dark value to the detector and stores it in memory for computing the zero point of CO and nitrogen cell intensities.

2. At time 1:15 minutes. The calibration source is moved out of the optical path and begins to heat up at a predetermined duty cycle.

3. At time 1:45 minutes.

(a) The held output flag clears and the analyzer returns to reading live CO.

(b) The hold flag is removed.

4. At time 7: 15 minutes.

(a) The heated calibration source is positioned in the optical path.

(b) The held output flag displays. The output is held at the last live CO value.

(c) The hold flag appears aaoss terminals JlO-2 and HO-3 on the control module’s rear terminal board.

(d) CO and nitrogen cell intensity values accumulate in the system memory. The values are compared to the intensity from the primary source.

NOTE

If values differ significantly, the calibration cycle reverts to step 2 with a higher or lower duty cycle, as appropriate.

The values are averaged and a ratio is computed. This ratio is used to compute FN56, calibration cycle zero factor. The new FN56 is inserted in equation (1) to recompute FN58, system operating zero factor, to the value which results in an absorption factor of zero in the CO computation. FN’s 56 and 58 are stored in system memory.

5. At time 8:30* minutes.

(a) A solenoid positions the calibration gas sell in the optical path.

(b) CO and nitrogen cell intensity values accumulate in system memory. Values are averaged and a ratio is computed. This ratio is used to compute FN52, calibration cycle span factor. The new FN.52 is inserted in equation (9) to recompute J?N54, system operating span factor, to a value which results in a correctly calibrated span. FN’s 52 and 54 are stored in system memory.

6. At time 9:45* minutes.

(a) The calibration source is turned off and is removed from the optical path.

@) The calibration gas cell is removed from the optical path.

7. At time 10:15* minutes,

(a) The held output flag clears and the analyzer returns to reading live CO.

(b) The hold flag is removed.

(c) The CAL cycle flag clears.

* In the event of the condition cited in the note in Step 4.(d), these times may be delayed by up to five six-minute increments. This is only likely to occur if power has been removed from the IR receiver module since its last automatic calibration cycle.

3-9. PEEK AND POKE SYSTEM MEMORY. To (peek) is to look at data in a memory address. To (poke) is to change data in a memory address. From time to time it may be necessary to access system memory, i.e., detector replacement, control module CPU circuit board replacement. To accomplish this requires familiarity with the following information.

NOTE

When accessing the peek and poke function (FN60) great care must be taken during address selection, data acquisition and data modification. Improper address selection and data modification may result in improper system operation thus requiring system reprogramming. If this occurs contact the factory (see back cover of this manual for the factory phone number) with the control module and detector serial numbers.

a. The Hexadecimal Number System. The hexadecimal number system is based on the number 16, whereas the decimal number system is based on the number 10. The example below is intended to I ! show what is meant by the numbers that both systems are based upon.

EXAMPLE

Decimal number 15,049 is made up of five digits located in five separate positions. The locations are [l] the 10,000 position, [S] the 1,000 position, [0] the 100 position, [4] the 10 position and [9] the 1 position. The decimal number can be written as follows:

(lx10,000) + (5x1,000) + (0x100) + (4x10) +(9x1) = 15,049

(10,000) + (5,000) + (0) + (40) + (9) = 15,049

As you can see, the decimal number system is based on the number 10 or the multiple of fhe number 10, as seen in the first example. (10,000) (1,000) (100) (10) (1).

For speed and convenience we will state the position values exponentially as seen below for the decimal system.

10,000 = lo4 10 = 10’ 1,000 = lo3 1=1oo

100 = 102

15,049 = (lxlti) + (5xld) + (0x102) + (4x10’) + (9xlOO)

15,049 = 10,000 + 5,000 + 0 + 40 + 9

Now that we have a basic understanding of the decimal system, let us look at the hexadecimal system.

The hexadecimal system is based on the number 16. This means that unlike the decimal systems, position being valued by multiples of the number 10, the hexadecimal system values it’s positions with the number 16.

IB-106SlOA 347

EXAMPLE:

Hexadecimal number 3AC9 has four positions:

[31 PI [Cl [91 We will state the position value exponentially:

131 (3~16~) 163 = 4.096 (3~4,096)

r91 (9x16’) 16’=1 W)

As in the decimal system, there are individual position factors (single digits) that give specific value to each position. In the hexadecimal system, they are as follows:

o=o 5=5 A= 10 1=1 6=6 B=ll 2=2 I=1 c-12 3=3 8=8 D = 13 4=4 9=9 E=14

With this understanding, we can translate the example number 3AC9 as follows:

[31 (3~16~)

WI @x162)

[Cl (C~16~)

(3~4,096) (~55) (QW (3~4,096) (10x256) (12x16) (12,288) ww (192) 15,049 = 12,288 + 2,560 + 192 + 9

F=15

[91 (9x16’) (9a

b. The Hexadecimal System Used by the 5100. Hexadecimal (BASE 16) notation is used to convert binary (BASE 2) numbers into a usable format for operators. Binary numbers are what computers use for all data transfer within the memory. The numbers can become very long, thus extremely tedious to enter using a keyboard. Hexadecimal numbers are used because they can be converted directly into binary numbers by the computer using a very short program and little memory. To read the contents of memory, or to store in memory new data values, it may be necessary to convert decimal (BASE 10) numbers into hexadecimal, and visa versa.

Table 3-3. Example Conversion

I DECIMAL HEXADECIMAL I DECIMAL HEXADECIMAL I

1 1 2 2 3 3 4 4 5 5 6 6 I I 8 8 9 9 10 a

11 B 12 C 13 D 14 E 15 F 16 10 17 11

25 19 26 1A

1B106510A 34

For very large numbers it is necessary to follow the conversion example listed below:

Converting Hexadecimal To Decimal Example: Example:

3~16~ = 3~16~ = 3 x 4096 = 3 x 4096 = 12288 12288 Ax16’= 10x 256= 2560 Ax16’= 10x 256= 2560 cX16l= cX16l= 12x 16 = 12x 16 = 192 192 9x16’= 9x 1= 9 9x16’= 9x 1= 9

Hexadecimal Decimal 3AC9= 15,049

CONVERTING DECIMAL TO HEXADECIMAL

15049,, =

940 16 15049

144 64 64

9

58 16 940

80 140 128

12

3 16 58

48 10

0 16 3

Least Significant Digit

Second Least Significant Digit - (12 =c )

-I Third Least Significant Digit (12 = A )

Most Significant Digit

3-10. HOW TO CHANGE ADDRESSES IN FUNCTION 60 @zek&Poke).

a. Press [6][0] displayed in LCD should be an address in the lower display and data in the upper display.

Example: 4000 Upper Display E2E Lower Display

b. Press decimal point key [.] display will change to four blinking zeros in upper display. The notation ADR (address) will be shown in the lower display.

Example: 0000 Upper Display Adr Lower Display

lFSX!&51OA 349

c. Many codes for addresses will be in both numbers and letters. Number values range from 0 to 9. The letters range is A, B, C, D, E, F; EE2E for example:

1. To enter a number, simply press the corresponding number key on the keyboard.

Example: Entering the number 4.

2. To enter a letter press the number [0], then, press the user key one time for every letter, F through A.

Example: Entering address. We will choose EE2E for the example.

(a) Press [O], then press the user key two times. You should then see: “OOOE” in the upper display.

NOTE

Numbers and letters can be scrolled through in the forward or reverse directions by pressing the decimal point or user keys respectively. To move the desired number or letter to the left one place, thus readying the control module for the next number or letter entry, a own- her key must be pressed.

(b) w ((0

(e)

Press [O]; press the user key two times. You should then see: “OOEE” in the upper display.

Press [2]. You will see: “OEE2” in the upper display.

Press [O]; press the user key two times. You should see the following display: “EE2E” in the upper display.

Press [STORE ENTRY]. You will see the following display: 4000 upper display.

E2E lower display This code is EE2E, however, the lower display will show only 3-l/2 digits.

3-11. HOW TO ENTER DATA INTO AN ADDRESS IN FUNCTION 60 week & Poke).

a. Call up the address you wish to start with (see paragraph 3-10.a).

b. Follow paragraph 3-10 to obtain the addresses in the lower display and the data in that address displayed in the upper display.

Example: 4000 Upper Display E2E Lower Display

c Press [STORE ENTRY] key.

d. If a factory code is asked for, go to 3-1l.e. If not, proceed to 3-1l.f.

e. Enter factory code [2][4][0][0]. Press [STORE ENTRY.

f. You should see zero (0000) flashing in the upper display and the address in the lower display.

IB-lC!6-510A 3.50

g. Enter the data in the same manner as the address entry (see paragraph 3-11.~).

NOTE

Numbers and letters can be scrolled through in the forward or reverse directions by pressing the decimal point or user keys respectively. To move the desired number or letter to the left one place, thus readying the control module for the next number or letter entry, a number key must be pressed.

Example: For this example we will enter the data VFW.

1.

2.

Press the [Cl] key.

Press the user key one time. You will see the following:

OOOF Upper Display Flashing E2E Lower Display

3.

4.

Press the [O] key.

Press the user key one time.

OOOF Upper Display Flashing E2E Lower Display

5. Press the [5] key. You should see: OFFS Upper Display Flashing E2E Lower Display

6.

7.

Press the [Q] key.

Press the user key one time. You will see:

FF5F Upper Display Flashing E2E Lower Display

8. Press the [STORE ENTRY] key. The data is now stored in the address:

FFSF Upper Display E2E Lower Display

9. Return address EE2E data to 4000 before proceeding.

IB-lM-51OA 3-51/n

SECTION IV. STARTUP AND CALIBRATION

4-1. GENERAL. This section describes the procedures required to startup and calibrate the Model 5100 CO Analyzer

4-2. PRE-OPERATION CHECK AND CONTROL SETTINGS. Check the Model 5 100 and set the controls as follows:

a. Apply power to infrared source module

NOTE

The IR scwce wilI take up to 45 minutes to reach its fuII operating temperature. When at operating temperature, the radiating surface of the IR source will be seen to gIow faintly red when viewed in a darkened room or across the duct or stack.

b. Check window assembly on the IR receiver module to be sure window is clean and slide. assembly is in the unobstructed position and fully inserted.

c. Remove the rear cover from IR receiver module.

d. Check that printed circuit boards ax fully seated and secured with thumbscrews, fuses are installed and all four cable connectors are secure (Figure 8.43).

e. Turn power on, with ALIGN/RUN switch (Sl), on the CPU board, in the RUN position (Figure 3.8). ‘Ihe dual cell should actuate every 2.112 seconds.

4-3. OPTICAL ALIGNMENT. The radiating surface of the IR source, approximately 4” (loan) diameter, must be viewed by the receiver module. In longer path length applications, careful optical alignment is needed.

a. Set intensity adjust pot, R18, of receiver CPU board (Figure 3-X) to its full clockwise position

b. Loosen four 3/X inch nuts of the receiver alignment flange to allow to area “seen” by the receiver to be adjusted.

c. Set ALIGN/RUN switch on CPU board to ALIGN position. This deactivates the dual gas cell solenoid.

d. Observe the column of LED’s, indicating intensity level, and move receiver in both the horizontal and vertical planes until the receiver observes the source (indicated by sequential illumination of individual LED’s up the column). An audible signal is also activated that provides a corresponding pitch for each LED indicator. If surrounding conditions render the LED’s and audible signals unusable, the EXT METER terminals are available for driving a voltmeter, O-2.5 VDC. Partially tighten nuts which secure the flange. Reduce intensity adjust setting so that the indicator is on scale and then finely adjust the receiver position to maximize the signal indicator. If necessary, reduce intensity adjustment setting so that the indicator is at the second LED from the top, or the voltmeter reads 1.80-1.90 Vdc, and repeat this procedure until the optical alignment is optimized and flange-securing nuts are tightened.

e. Return ALIGN/RUN switch to RUN position and replace cover.

4-4. INITIALIZE CONTROL MODULE.

a. Loosen upper and lower screws of hinged front cover, allowing cover to open downward.

b. Loosen four captive retaining screws of keyboard/display and carefully remove keyboard/display.

NOTE

The ribbon cable connecting the keyboardldisplay to the CPU board need not be dis- connected.

Check to ensure that all printed circuit boards are fully inserted into their comectors. Replace the keyboard/display.

c. Apply power. The lower LCD should display “CO”.

d. Test the display using FNG9, DISPLAY TEST, and the following keystroke sequence:


(1)

(2)

[01[91 All segments All flags display display

Depress CO key to exit FNOS. The lower display should retUrn to “CO”.

e. The remaining functions to be accessed during start-up procedures are user locked and will require entry of the user code into the system to allow adjustments. The user code may be displayed by depressing keys [3] [O]. The analyzer is shipped t?om the factory with a user code of 5100 (see paragraph 3-7, to change or bypass the user code). When the user code has been entered to access a user locked function, all user locked functions are unlocked and will remain so until such time as the user initiates no keystrokes for a contirmous period of five minutes, at which time the function become locked once again.

f. Select FE’S unit system (degrees Farenheit, feet) or the INKS unit system (degrees Celsius, meters). The analyzer is shipped in the MKS unit system. Use FN23, system units, and following keystroke sequence:

KEYSTROKE DISPLAY UPPER LOWER

(1) PI [31 0 dr 1 23 Display “0” indicates MKS unit system Display “1” indicates FPS unit system

(2)

(3)

(4)

(5)

(5)

(6)

To change: [STORE ENTRY]

PI 111 PI PI

[STORE ENTRY]

If MKS desired: [STORE ENTRY

Or, if F’PS desired: PI

[STORE ENTRY]

CODE USE

5100 (Flashes) USE

0 (Flashes) 23

0 (Steady) 23

0 (Flashes) 23

1 (Steady) 23

g. Set the path length in meters or feet, as selected in FN23, using FN24, path length, and the following keystroke sequence:

KEYSTROKE

(1) r21141

(2) [STORE ENTRY]

(3) MMI.lMM

(4) [STORE ENTRY]

DISPLAY UPPER LOWER

xX.xX 24 (Current path length)

0 (Flashes) 24

YY.YY 24 (Desired path length) (Flashes)

YY.YY (Steady) 24 I FLAG

M or Ft

M or Ft

h. Select automatic or manual flue gas temperature compensation.

1. Automatic. Flue gas temperature probe provides data used by the microprocessor to compute temperature compensated CO concentration values. The analyzer is shipped from the factory programmed for automatic temperature compensation. Check the MAN GAS T flag. If this is not displayed, the system is programmed for automatic gas temperature compensation mode, FN27 displays as “0”.

If manual compensation is selected as described below and it is later desired to return to automatic, use FN27 and the following keystroke sequence:


(1) PI [71 xxx 27 oCOrOF

(2) [STORE ENTRY] 0 mashes) 27

(3) [STORE ENTRY] 0 (Steady) 27

2. Manual. The flue gas temperature value used by the microprocessor to compute temperature compensated CO concentration values is mammlly selected using FN27 and the following keystroke sequence:

KEYSTROKE DISPLAY UPPER LOWER

(1) PI 171 0 27


(3) [xl tx1 [Xl XXX (Flashes) 27

(4) [STORE ENTRY] XXX (Steady) 27

FLAG

TorOF

i. Select the full scale range using the 2nd RANGE function as described in paragraph 3-4.g.

j. Select analog output format. Four selectable, isolated analog outputs are available: O-20 mADC, 4-20 mADC, O-5 mADC or l-5 VDC. Any one may be selected by using the appropriate terminal connections on the control module (Figure 2-7) and FN22, Output Mode. The analyzer is shipped from the factory programmed for 4-20 mADC or 1-S VDC operation. To select O-2 mADC or O-5 VDC, use the following keystroke sequence:

KEYsTRoKFi DISPLAY FLAG UPPER LOWER

(1) PI PI I1 22 Display “1” indicates that 4-20 mADC or l-5 VDC is available at rear terminals.


(3) [STORE ENTRY] 1 0 (Steady) 22 Display “0” indicates that O-20 mADC or O-5 VDC is available at the rear terminals.

rE10651oA 4-l

k Select output truncation format. In the normal course of operations, occasional negative ppm values are to be expected as a result of noise and transients. If the 4-20 mADC (or l-5 VDC) option was selected, such negative readings will generate an output of less than 4 mADC (or less than 1 WC), i.e., a “lie” zero. Alternatively, FN40 permits truncation of the ppm readings at zero, both in the display and in the analog output. The analyzer is shipped from the factory programmed in the truncating mode. If the “live” zero is desired, use the following keystroke sequence:

KEYSTROKE DISPLAY E-LAG UPPER LOWER

(1) [41101 IO 40 Display “0” indicates truncation of negative ppm to zero.

(2)

(3)

(4)

[STORE ENTRY 0 (Flashes)

PI 1 (Flashes)

[STORE ENTRYJ 1 (Steady) Display “1” indicates “live” zero.

40

40

40

1. Select the time constant of the analyzer, in seconds, using the 2nd RESP TIME function as described in paragraph 3-4.b.

tn. Set alarm 1 and 2 setpoints and deadbands, in ppm and make higMow selections using the 2nd alarm 1 and alarm 2 functions as described in paragraphs 3-4.n and 3-4.0.

n. Set automatic calibration frequency. The automatic calibration cycle is initiated by the microprocessor at a frequency which is adjustable from once per hour to once per 255 hours. Normally, this is set at once per 24 hours and this is the setting which is made at the factory. To change the frequency, use FN20 and the following keystroke sequence:

KEYSTROKE

(1) PI PI

(2) [STORE ENTRY]

(3) WI [xl [xl

(4) [STORE ENTRyI

DISPLAY UPPER LOWER

24 20

0 (Flashes) 20

XXX (Hours) 20 (Flashes)

XXX (Steady) 20

NOTE

FLAG

An entry of [O] disables the automatic initiation of a calibration cycle.

IBlOE-SlOA 4-s

4-5, ZERO CALIBRATION. Initiate a zero calibration cycle using the 2nd SET ZERO function as described in paragraph 3-4.f.

NOTE

A valid zero calibration requires boiler air/fuel ratio adjustment. Please follow the proce- dues of Section 3.33.3.1, Par. 6, ~30, in using the 2nd set zero hmction.

Check that the fault flag in the lower display is clear. If not, use the 2nd diagnose function, as described in paragraph 3-4.m, to determine the problem and refer to Section 7, for possible corrective actions.

The system is now fully commissioned for operation. It is recommended that the set of system operating parameters established in the startup and calibration procedures be stored in system memory per the procedures of paragraph 3-4.j. This ensores that the set, as originally established, may be restored at any time, regardless of any interim changes that may be made.

Table 3-1 may be used to record these system operating parameters as well as other sets of parameters to be stored in system memory for various boiler operating conditions. Reference to the table will then allow quick retrieval of a given set of parameters when necessary.

SECTION V. ACCESSORIES

5-1. INTERCONNECT CABLE. The interconnect cable consists of a shielded 3 conductor, 22 AWG cable. This cable is used to connect the infrared receiver module to the control module.

5-2. THERMOCOUPLE WIRE. The thermocouple wire consists of a type K, 24 AWG, wire. lids wire is used to connect the infrared source module to the infrared receiver module and flue gas temperature probe to the infrared receiver module.

5-3. SOURCE PURGE AIR ASSEMBLIES.

a. Theory of Oueration. The IR source module is installed with the source surface flush with the inner wall of the duct in most applications. Therefore, the source is subject to only minimal coating or particulate buildup, consequently there is no purge air requirement to maintain source cleanliness. However, in certain applications, such as Kraft recovery units, and in some waste incinerators, the flue gases contain constituents which can adhere to the source surface (despite the bigb surface temperature) and damage the source through corrosion. In these applications, to protect the source and reduce the need for periodic manual cleaning of the source surface (to maintain sufficient radiated intensity for proper analyzer operation), a source purge air is required. Two types of purge air assemblies are available; jet pumps or purge air blower.

b. Source Purge Air Assembly with Jet PU~DS. This source purge air assembly consists of a carbon steel sleeve fitted with two jet pumps, one on either side (Figure 5-l). (The jet pumps are identical to that used with the IR receiver module with the exception that they are not equipped with filters.) The purge assembly is installed on the standard source mounting sleeve and the source module is then installed in the purge assembly. Procedures and hardware for installing the source module in the purge assembly are identical to those for installation in the standard mounting sleeve.

When installed, the source surface is recessed from the duct wall at the rear cavity created by the mounting sleeve and the active, forward section, of the purge assembly. A user supplied compressed air supply is connected to the l/4-inch tube fitting on each jet pump. Compressed air requirements are 6 SCFM (2.7 I/S) at 60 psig (413.7 kPa gauge), 3 SCFM (1.35 I/S) at each fitting. The jet pump is designed to accept the compressed air and induce a low pressure, high volume flow of ambient air through the purge assembly. The two jet pumps produce properly directed flows of sufficient volume to effectively purge the cavity, shielding the source from flue gases.

Four brass plugs are located around the perimeter of the forward section of the purge assembly. If the duct pressure is negative, the plugs should be removed to induce additional purge air into the assembly. Do not remove the plugs if the duct pressure is ever positive.

IBlCGSIOA s-1

l/4 - 20 x 1.00 LG NP. 8 PLACES MOUNTING

HARDWARE ON 9.375 INCH BOLT CIRCLE (SUPPLIES)

I.R. SOURCE MODULE CARBON STEEL SLEEVE

(SEE INSTRUCTION DWG P.N. ,700,0,)

PURGE AIR l-114 NPT x 3/4 NPT

FOR REMOVAL

Figure 5-1. Source Purge Air Assembly with Jet Pumps

c. Source Purw Air Assemblv with Blower. This source purge air assembly consists of a carbon steel sleeve fitted with two hose adaptors, one on either side (Figure 5-Z), a blower, blower hose, and hose clamps. (The blower is identical to that used with the IR receiver module.) The purge assembly, with hose adaptors,, is installed on the standard source mounting sleeve and the source module is then installed in the purge assembly. Procedures and hardware for installing the source module in the purge assembly are identical to those for installation in the standard mounting sleeve. Installation of the blower is identical to the procedure used for connecting the blower with the infrared receiver module.

When installed, the source surface is recessed from the duct wall at the rear cavity created by the mounting sleeve and the active, forward section, of the purge assembly. The blower is mounted away from the duct at a location where it can draw in clean fresh air. The sleeve hose adaptors are connected to the blower with hoses and introduce a low pressure, high volume flow of ambient air through the purge assembly. The two hose adaptors deliver properly directed flows of sufficient volume to effectively purge the cavity, shielding the source from flue gases.

Table 5-l. Accessory Part Numbers

I ~~~ PART NO. I DESCRIPTION I

9200177 Interconnect Cable 9200178 Thermocouple Wire 2295240 Source Purge Air Assembly with Jet Pomps lNO4968GOl Blower and Hose Adaptor Kit

lB-lM-51OA 5.3

AIR PURGE

114 - 20 x 1.00 LG PIP. HOSE ADAPTOR

8 PLACES MOUNTING HARDWARE ON 9.375 ,NCH

BOLT CIRCLE (SUPPLIES)

SLOT40;.4C;i14 LG

I 2.41 i-j- 3.25 -1 .‘“~771

BOTTOM VIEW

PURGE AIR BLOWER *,

l-1/4 NPT x 3/4 NPT REDUCED BUSHINGS

FOR REMOVAL

Figure 5-2. Source Purge Air Assembly with Blower and Hose Adapter

SECTION VI. CIRCUIT DESCRIPTIONS

6-1. OVERVIEW. The circuit descriptions are intended to expand the understanding of components operation. This section can not explain all possible interrelationships, but can expand operational understanding so that troubleshooting to the sub-assembly level will be more easily accomplished.

6-2. TEMPERATURE CONTROL (SOURCE). The source temperature control section of the Model 5100 monitors and controls source temperature and IR emissions. A solid state triac opens and closes, providing AC voltage to the heating coils on a variable duty cycle as required, to maintain a constant temperature. mo type K thermocouples are used to feedback temperature information to the controller as well as to the receiver for diagnostic purposes. A schematic of the main source temperature control, Figure 6-1, is provided for further information.

Control TC (Thermocouple) provides a very small voltage input through TB2-2 to pin 3 Ul (MP5507B2). The voltage is then amplified and passed to U2-A pin 2 (TLO821P). The cold junction is added to the input from VR1 (LM335Z) and then is passed to U2-B which acts as a comparator. When the voltage at pin 5 passes below reference voltage established by voltage divider (set-point), the input voltage to the gate of Ql (VN2222LM) is +12 WC. An OFF condition will cause U2-B to output a -12 VDC. In the ON state, an AC voltage is conducted to the heating element coil BTl-4 through triac Q2 (SC147E). Power is supplied by the bottom board of the stack. Outputs from VR2 = +12 VDC, VR3 = -12 VDC.

6-3. RECEIVER CPU (CENTRAL PROCESSOR UNIT).

a. Description. The receiver CPU section of the Model 5100 receiver controls all software and ~~ hardware functions to the receiver. All mechanical and timing actions of the receiver are constantly monitored by the CPU for correct operation. Readings from the optical bench as well as temperature information from the flue gas and source assembly are transmitted via a RS-422 link to the control module.

The receiver CPU card can be divided into six sections as follows:

1. CPU Section 2. Watch Dog Section 3. Memory Section 4. Address Decoder Section 5. I/O Section 6. Analog Section

I

Most of the communication between these sections is rooted through the system’s address, data and control buses.

The system address bus is composed of 16 address lines and is generated by the CPU (UlO, Figure 6-2) to control the source and/or destination of the data transfer.

The system data bus is a bidirectional bus having eight data lines.

The system control bus consists of read/write enable, interrupt request, non-maskable interrupt (NMI), reset signals, VMA (Valid Memory Address, and E.[lMHz clock]).

The receiver CPU board receives +5 VDC, +12 VDC, -12 VDC from the power supply card. The +5 VDC enters the receiver CPU at P4, pin 6 and pin 7, the +12 VDC and -12 VDC enter at P4, pin 5 and P4, pin 11, respectively. The +5 VDC powers all of the digital logic and the +12 VDC and -12 VDC are regulated down to +5 WC and -5 VDC to power all of the op amps and analog references.

b. CPU Section. The CPU section consists of a 4 MHz crystal oscillator circuit (Yl, Cl, C2) and a microprocessor (UIO). The CPU divides the 4 MHz down to generate the 1 MHz enable clock. The microprocessor is a Motorola 6802, featuring a one chip clock plus 128 bytes of internal RAM. All intelligent decisions of the receiver module are made by the microprocessor. The address bus, bidirectional data bus and control bus allow the processor to exercise direct control over the rest of the sections.

c Watch Doe Section. The watch dog section consists of a clamp circuit (CRI, CR2), a Schmitt trigger circuit (U19B, U19C, U19D), binary counter and decoders (U20, U27A, U27C, U19A, Q2). 60 Hz or 50 Hz AC signals are supplied by the power supply. These signals are clamped by the clamp circuit and then converted to a square wave by the Schmitt trigger circuit. The square wave is a clock input to the binary counter to generate a non-maskable interrupt to the CPU every OS1 seconds. The CPU, in turn, resets the counter, then services the NMI to insure the program has been run in the correct sequence; otherwise a software reset occurs. In the event the CPU does not service the NMI for 2.672 seconds, or if the CPU is trying to access an illegal address, the watch dog will generate a system reset.

’ 32 counts = 0.53 seconds at 60 Hz or 0.64 seconds at 50 Hz. 2 160 counts = 2.67 seconds at 60 Hz or 3.2 seconds at 50 Hz.

d. Memorv Section. The memory section consists of 128 bytes of RAM in the CPU (UIO) and 4K of EPROM (U13). The EPROM contains the receiver system program located at address FOOOH to FFFFH (paragraph 3-9.a).

e. Address Decoder Section. The decoder section consists of UlZA, U12B, U27A. U12B decodes addresses from OOOOH to 03FFH. The output of U12B is -SO, -Sl, -S2, -S3 corresponding to the following addresses:

-SO = OOOOH to OOOFH -Sl = OOlOH to OOlFH -S2 = 002OH to 002FH -S3 = 003OH to 003FH

U12A is used to select the high and low byte results of the A/D converter. U27A is an illegal address decoder for the watch dog.

f. I/O Section. The I/O (input/output) section is a memory mapped I/O and consists oE UllD, CR4, Ql, U14, U18, U23, U15, U16, U17, U26, .I24 and U25. U14 and U23 are Motorola 6840 timers, each containing three independent programmable timers. Timers 1 and 3 of U14 together provide a pulse width, modulated signal at U14 to drive the impulse width, modulated signal at U14 to drive the integrator UlB to control the chopper motor speed. Timer 2 of U14 is the software timer. Timer 1 of U2.3 generates a 21 KHz clock for the A/D converter. Timer 2 of U23 is the buzzer timer. Timer 3 of U23 is the cai (calibration) source duty cycle timer. U15 is a Motorola Peripheral Interface Adapter (PIA). The chip has two ports and each port has eight I/O lines which can be programmed for either input or output. There are also two special I/O lines, CB2, CA2, which can be programmed as input or output (CBl, CA1 are input only). As an input (CAl, CBl, CB2) the can be either Negative or Positive edge triggered as used with a photo chopper and AD converter (CAl, CBl, CB2). U18 is an integral, 12 bit A/D converter. The input to the AiD converter is from U16 and U17. To run the A/D converter, the CPU programs the PIA to output a high at PA7, then when the conversion is completed, the A/D output a low to the CA1 input to the PIA. In turn, the PIA generates an interrupt request to the CPU to inform the CPU of a complete conversion. An overrange will occur if the analog input to the A/D converter is more than twice the reference voltage, or four times test point 6.

15106510A 63

DWG NO. 2400190

Figure 6-2. Receiver CPU Circuit Card Schematic (Sheet 1 of 2)

4 il ‘!” , L----. I. \

/i, , , [ \I / , (

IE10651OA 6.5

. 3suc I

INTENSITYTHROUGH

CARSON MONOXIDE CELL

Figure 6-3. Detector Output (Waveform TP-13) Receiver Card CPU Board

U16 and U17, together, become a sixteen channel analog multiplexer for the A/D converter. To select a channel for conversion, the CPU programs the PIA to output a binary code corresponding to the selected channel at PAO, PAl, PA2, and PA3.

U24 is an Asynchronous Communication Interface Adapter. This chip is programmed by the CPU to handle the communication between the receiver and the control module.

U2.5 provides the communication link with the control module.

g. Analog Section. The analog section consists of: U21C, UlC, U2D, VR3, U21, U22, UIB, UlA, U3, U4, U22A, U22B, U2lA, U21B, US, UlD, U2A, U2B, and U2C. UlB is an integrator, driving the chopper motor.

UlA is the CAL SOURCE TEMP amplifier. The amplifier provides a gain of 75 times and has an output range tiom zero to 2.5 VDC.

U4 is the SOURCE TBMP amplifier. The amplifier provides a gain of 56 times and has an output range from zero to 2.5 VDC

U3 is the GAS TEMP amplifier and provides a gain of 107 times and has an output range from zero to 2.5 MC.

U5 is a four channel multiplexer. The chip is controlled by the chopper motor frequency and PBO to transfer the analog signal from the detector to one of four sample-and-hold amplifiers. U2A, U2B. U2C and U2D are sample and hold amplifiers. VR3 is the cold junction ‘IEMP, and acts as a. reference of the gas and source TEMP readings.

The analog signal from the detector (Figure 6-3) is conditioned by a high pass filter (C20, R20) and amplified by UID. The gain of UlD is set at the time of alignment by adjusting RI8 according to the intensity of the analog signal. To set the gain for UlD, switch the alignment switch to the ALIGN position, then adjust R18 until the second LED from the top of CR4 lights up.

UlC is a sample-and-hold amplifier which is used in the alignment mode.

6-4. RECEIVER POWER SUPPLY BOARD. The power supply section of the Model 5100 receiver accepts 115iZ30 VAC input and provides AC/JX voltage output as required by the CPU for hard/software inputs. Voltage levels are monitored by the CPU at critical points (i.e., AiD converter, chopper motor, etc.) for diagnostic purposes. Refer to Figure 6-4.

IB106410A 6.6

I I

_. ._ .^

IB-106-510A6-7/6-8

a. AC Voltage. The AC voltage is sent to transformers Tl and T2, T2 secondary voltage is rectified by CR1 (3N254/MDA201), the output of which can be seen at test point 6 as +35 MC, 515 VDC. U7 (LM317K) further regulates this voltage to 19.2 VDC 20.7 VDC (test point 5) which is Sent to ANA 2 (receiver CPU card multiplexer U17, pin 1.5) and P2, pin 3, dual gas cell solenoid.

b. Tl Secondarv Voltaee. The Tl secondary voltage is rectified by CR2 (3N247/MDAlOlA), the output of which can be seen at test point 7 and 8. Test point 7 = +24 VDC, 510 VDC; test point 8 = -24 VDC, +lO VDC. U3 and U4 (U3-7812, U4-7912) farther regulate the voltages to test point 1 = +12 VDC, 50.6 WC and test point 2 = -12 VDC, 20.6 VDC. Tl, secondary 2, provides AC voltage to CR3 (3N254/MDA201) which regulates the voltage to +16 VDC, 29 VDC at test point 9. Voltage is further regulated to +5 VDC, to.25 VDC at test point 3.

e. AC Voltage. AC voltage is also provided directly to the source of Q2 through fuse I?2 (lA, Slo Blow, 25OV) to provide AC to the cal heater when required. Fuse 1 (lA, Slo Blow, 25OV) provides protection for Tl and T2 primary.

d. Solenoid Triacs. The solenoid triacs are located on the power supply card. They are Q3, Q4 and Q5 (TIP120). A positive, unregulated 25 VDC is supplied at one side of the calibration cell solenoid and the calibration source solenoid. The other side of the cal cell solenoid is input to the collector of Q4. The other end of the cal source solenoid is input to the collector of QS. When the CPU requires either solenoid to energize, it will cause a +3 VDC output to the base of the appropriate triac. This will in turn, cause the triac to conduct the collector emitter to circuit common, thus energizing the solenoid. The solenoid for the dual gas cell assembly is powered by triac Q3 (TIP120). One side of this solenoid is fed by 19.2 VDC +0.7 VDC (TP5). The other side of the solenoid is input to the collector of Q3 which operates in the same manner as Q4 and Q5.

Due to the extra load caused by the operation of the dual gas cell solenoid (on and off every five seconds), a voltage boost is provided to the base of Q3 by Q6 (2N5210). Q6 provides a load buffer to prevent (PBO) signal from being loaded by Q3 operation.

e. Triac Circuit for Calibration Source. A duty cycle square wave, (high state 2.5 to 5 VDC, low state 0 to 0.8 VDC) is established by the CPU card at the gate of Ql (VN2222LM). Ul transmits this signal optically which will cause a corresponding AC voltage at zero cross over voltage to the gate of Q2 (SC147E). Thus the AC voltage to the cal source will be on or off, based on the duty cycle established by the CPU.

6-5. CONTROL MODULE CPU.

a. Descriution. The control module CPU card can be divided into five sections as followa

1. CPU Section 2. Watch Dog Section 3. Memory Section 4. Address Decoder Section 5. I/O Section

All of the comniunication between the sections are routed through the system’s address, data and control buses.

The system address bus has 16 address lines and is generated by the CPU (Ul, Figure 6-5) to control the source and/or destination of data transfer.

The system data bus is a bidirectional bus having eight data lines.

El-10651OA 6.9

- - - -

DWG NO. 2400186

~Figure 6-5. Control Mod& CPU Circuit Card Schematic (Sheet 1 of 2)

I&10651OA 6.10

n

DWG NO. 2400186

Figure 6-5. Control Module CPU Circnit Card Schematic (Sheet 2 of 2)

lBlW5IOA 6.11

The system control bus consists of read/write, enable, interrupt request, non-maskable interrupt (NMI), reset signals and VMA (Valid Memory Address) and E (1 MHz clock).

The control module CPU receives +5 VDC, from the power supply card. The +5 WC input to the control module CPU’s at Pl, pin 23A and pin 23C. The +5 VDC powers all of the digital logic circuits.

b. CPU Section. The CPU section of the 5100 control module accepts receiver module readings, temperature, and diagnostic information. All computational and display functions are handled by the CPU section of the control module. All user input operating parameters, as well as factory input optical characteristics of the instrument are located in the memory section of the CPU.

The CPU section consists of a 4 MHz crystal oscillator circuit (Yl, ClO, Cll) and a microprocessor (Jl). The CPU divides the 4 MHz down to generate the 1 MHz enable clock. The microprocessor is a Motorola 6802, featuring one chip clock plus 128 bytes of internal RAM.

All intelligent decisions of the control module are made by this microprocessor. The address bus, bidirectional data bus and control bus allow the~processor to exercise direct control over the rest of the sections.

c. Watch Dog Section. The watch dog section consists of a clamp circuit (CRl, CR2), a Schmitt trigger circuit (U3B, U3A), a binary counter, and decoders (U4, U17A Illegal Address Decoder, U3D, U3C, Ql). The 6OHz or 50 Hz AC signals are provided by the power supply. These signals are regulated and clamped by the clamp circuit and then converted to a square wave by the Schmitt trigger circuit. The square wave is a clock input to the binary counter which generates the non-maskable interrupt to the CPU every 05 seconds. The CPU, in torn, resets the counter, then services the NMI to ensure the program has been run in the proper sequence, otherwise a software reset occurs. In the event the CPU does not service the NMI for 2.67 seconds or if the CPU is trying to access an illegal address, the watch dog will generate a system reset.

d. Memory Section. The memory section consists of 128 bytes of RAM in the CPU (Ul) and an additional 2K bytes of RAM in UlO. The memory section ROM consists of 512 bytes of EEPROM in U8, 4K of EPROM (U9) and 4K of EPROM (U3) in the output card. The control module system program has about 8K bytes of code residing in the two 4K byte EPROM’s The first 4K are in U3 of the output board and the second 4K are in U9 of the CPU board. U5A, U5B, and U7A are the write protection circuits for the EEPROM. Every time the CPU wants to write into the EEPROM, it must first program the PIA to output a low at PB7. It will then begin the write cycle.

e. Decoder Section. The decoder section consists of U6, U7B, U7C, U17A, U17B. U6 decodes addresses from SOOOH to FFFFH. The outputs of U12B are 8ooo’, 9000’, AOOO’, BOOO’, COOO’, DOOO’, EOOO’, FOOO’. They will go low, corresponding to the following addresses.

8000’ = 8000H to 8FFFH 9000’ = 9000H to 9FFFH AOOO’ = AOOOH to AFFFH BOOO’ = BOOOH to BFFFH COOO’ = COOOH to CFFFH DOOO’ = DOOOH to DFFFH EOOO’ = EOOOH to EFFFH FOOO’ = FOOOH to FFFFH

U17A, U7C, U7B are an illegal address decoder for the watch dog.

U2A, U2B, U2C are read and write decoder logic circuits. U17B is the data bus buffer enable for decoder logic.

f. It0 Section. The output section of the Model 5100 control module receives a computed part per million (ppm) CO level signal from the CPU section. The output ranges are user configurable. The isolated range outputs are O-20 mADC/O-5 VDC or 4-20 mADC/l-5 VDC, proportional to the full scale range selected.

The J/O section is a memory mapped I/O and consists of Ull, U12, U13, U14, U15, and U16.

U13 is a Motorola peripheral interface adapter (PIA). This chip has two parts and each part has eight I/O lines. They can be programmed to be either input or output. There are also four special I/O lines (CB 1, CB2, CA1 and CA2) which can be programmed as input or output. As input they can be either Negative or Positive edge triggered. In this application CA1 and CBl are input with port one and port two which are programmed to handle the key board and LED display.

U12 is an Asynchronous Communication Interface Adapter. This chip is programmed by the CPU to direct the communication between the receiver and the control module.

Ul 1 is the binary counter used as a timer to energize the display buzzer.

U14 is the data buffer for the output card. This buffer is enabled only at address, SGGOH and above,

U15 and U16 are address buffers for the output card,

6-6. CONTROL MODULE OUTPUT CIRCUIT BOARD. The output PCB is an optically isolated current/voltage output source. The percent output level is based on the CO reading in relation to the range selection in Fn21 and the output zero point selected in Fn22. Refer to Figure 6.6.

Example: 1. With Fn21 set at 5000 (full scale value). 2. With voltage output O-5 VDC, current output O-20 mA (Fn22 = 0).

CO Reading output output Value 5000 ppm 100% 20 mA or 5 VDC 3750 ppm 75% 15 mA or 3.75 VDC 2500 ppm 50% 10 mA or 2.5 VDC 1250 ppm 25% 5mAor1.25VDC

a. Components Not Used in Outrmt Generation.

U3 PROM - used as memory for CPU control

UlO PROM ~ used as memory for CPU control

U2 ACIA - RS-232 to PC

U9 Circuit - EEPROM write protection circuit to provide a low reset to CPU with loss or fluctuation of +5 volt supply

U4 - RS-232 to PC

U5 Pins (2,3,4,5,6) - RS-232 to PC

U16 - provides communication link with receiver module

J

-

DWG NO. 2400187

Figure 6-6. Control Module Output Circuit Card Schematic (Sheet 1 of 2)

I-

i o-5V/I-5”

DWG NO. 2400187

Figure 6-6. Control Module Output Circuit Card Schematic (Sheet 2 of 2)

b. Circoit Oueration. The control CPU will cause a change in the timing of the duty cycle at Ul, Pin 3, based on CO in parts per million with respect to the range. This square wave will then be input to the gate of Ql (VN2’222LM). when the gate at Ql is high, it will cause the LED in U8 (4N27) to be on. The photo sensitive transistor section of U8 will sense light transmitted by LED section of U8, thus providing optical isolation.

The wave form at TPI will be the duty cycle square wave created by U8 and Q4. The wave form at IF1 will be -3.4 VDC with respect to TP2 common. U7 (TL083) integrator combines the signal (duty cycle) with reference the voltage at TP3 (2.5 VDC) to cause a voltage change at the emitter of Q6 and a current change at the collector of Q6 and Q7 with respect to output point A32 voltage constant (+2.5 VDC) and CT31 current constant.

Pictured in Figure 6-7 is a representation of the duty cycle wave form which will be seen at different percentages of the range (Function 21).

Whenever the CPU receives a reset signal, a low voltage level is simultaneously applied to pins 12 and 13 (of U5), causing a high state to be sent to the gate of Q2. This condition causes a low on the drain of Q2. This causes the LED section of U8 to be on all the time that a low voltage is present on pins 12 and 13 of U5.

VR4 (7915) provides conversion of isolated AC voltage to +I5 VDC, -15 VDC (power supply for secondary output circuit); voltage supply for primary output circuit from control unit.

WHERE: PPM 43% oi PN. 3%

30% Dun CYCLE OUYPUY - 1 VDWmA

WHERE:

PPM = w%ofPy.n. 30%ouYYcYcLE

olJlPuT=3VDCn3mA

WHER+ PPY I gO% ot PN. Zl. 30% DUYY CYCLE

OUYPUY - 4.3 VDcn3nlA

-

CO% ON 10% OFF ,

L-- T

-90%

PERIOD I 5.2 seconds

- OVDC

a -3VDC

- OVDC

- -3VDC

- OVDC

- -3VDC

Figore 6-7. Duty Cycle (TIT)

6-7. CONTROL MODULE POWER SUPPLY. The power supply section of the Model 5100 control module accepts llS/230 VAC and provides appropriate voltage levels for computation, display and output of ppm CO values. Appropriate voltage levels are also provided for alarm triacs and one Form C dry contact.

This PCB provides DC power for control module operation. The board also provides three alarm closure points. These consist of two triac and one dry contact alarms. Refer to Figure 6-8.

a. Tl Transformer. The Tl transformer provides three secondary sections for output. Section 1 provides 15 VAC through the F2 fuse to the isolated output section of the current output card through A16, and Al% Section 2 provides 15 VAC through the F3 fuse to CPU PCB for watchdog circuit and to (C18), CR3, CR4 which, in turn, regulates to voltages of -24 VDC, +I0 VDC at test point 2. These voltages are then regulated by U6 (7812), U7 (7912) to +12 VDC, and -12 VDC respectively (C26 = +12 VDC) (A28 = common) (A24 = -12 VDC). Section 3 provides 10 VAC through fuse F4 to CR2 (MDA 201/3N254). CR2 regulates AC voltage to +16 VDC, 9 VDC at test point 3, then US (LM209K) supplies +5 VDC to (A26 = +5 VLX) (C-28 = common).

b. Alarm Sections. Alarm 1 energizes in the following manner: +2.4 to +5 VDC is input through (A22) to gate of Ql (VN2222LM). This causes current flow drain to source (20 mA) through Ql and primary section of Ul and U2. This will cause the secondary section of Ul, U2 to provide AC voltage to the gate of Q4 (SC147E) at zero voltage cross over (AC). This causes a path for AC voltage from (A4, C4) to (A6, C6). VRl (V275LA2) acts as a glitch tilter to eliminate spiking.

Alxm 2 acts in the same manner as Alarm 1 (see previous paragraph), except that it is activated through C22.

Alarm 3 is a composite (process/fault) alarm. This means that when any alarm condition occurs, as in alarm 1, alarm 2, and/or fault, alarm 3 will close a dry contact. This occurs with +5 VDC output (PBO), pin 10 of U13 on control CPU board. This signal is initiated by the software programming of the CPU Ul.

ELlW51cL4 6-17

f

Figure 6-8. Control Module Power Supply Circuit Card Schematic

SECTION VII. TROUBLESHOOTING

7-1. DIAGNOSTICS PROGRAM.

The Model 5100 CO Analyzer executes a continuous program of self-interrogation for diagnostic purposes. Key data from the IR source. module, IR receiver module and flue gas temperature probe are monitored by the control module CPU, Data is checked against pre-programmed limits. Upon sensing a diagnostic parameter outside of pre-programmed limits, the CPU, through logic analysis, isolates the source of the abnormality and issues a fault flag. The fault or error is assigned a diagnostic code number used to identify the fault or error to the user. The following sections describe how the analyzer alerts the user to a fault/error, procedures for fault/error identification and the types of fault&as detected by the system.

7-2. FAULT/ERROR ALERT.

Upon detecting one or more fault/error conditions in the system, the control module CPU alerts the user to this condition in several ways simultaneously.

a. Fault Flag. The fault flag indicates that the microprocessor diagnostics program has detected one or more fault/error conditions in the system. The fault flag displays regardless of the operational state of the analyzer alarms or the nature of the fault/error. The flag will continue to display until such time as all fault/error conditions have been corrected.

b. Audible Alarm. The control module audible ahvm provides a locally audible alert to an unacknowledged fault/error condition, provided the analyzer alams are enabled (normal operational state). The audible alarm is activated regardless of the nature of the fault/error. To silence the audible alarm, depress the ACK ALARM key. The audible alarm will remain silent until the occurrence of a new fault. In the case of an intermittent fault, the audible alann may be reactivated if the fault clears and then occurs again.

c. M. The alarm 3 relay is energized upon detection of a fault/error condition in the system, provided that the analyzer alarms are enabled (normal operational state). To de-energize the relay, until the next occurrence, depress the ACK ALARM key.

NOTE

Both the audible alarm and alarm 3 are activated with the setpoint alarms, Alarm 1 or alarm 2. They do not necessarily indicate a fault/error condition. The cause for activation is determined by checking display flags: alarm 1, alarm 2, and fault.

d. Held Output Flag. Display of the held output flag in conjunction with an indicated fault/error condition signifies that the fault/error is a system-disabling one. Upon detection of a system-disabling fault/error, the displayed ppm reading and the analog output signal are held at the last valid live CO value. This occurs regardless of the operational state of analyzer alarms. The output is held until such time as the fault/error condition has been corrected. The user can manually set the held output to a different value (test value) by using the keystroke sequence described in paragraph 3.4.a. If this is done, the manually selected test value will have to be manually removed after the fault has cleared (paragraph 3.4.i). If the test value is removed before the fault has cleared, the display will return to the original held output, i.e., the last valid live CO value prior to the fault.

e. Hold Flag. Concurrent with the held output flag, and under the same fault/error conditions, the system issues a hold flag. The flag signals appears at terminal 29 at the rear of the control module and fully described in paragraph 3-6.~. The hold flag is maintained throughout the duration of the held output mode.

f. Receiver Startoe. When the IR receiver module is first turned on, or goes through a power intermp- tion, it will transmit a few records with incomplete data. The control module will fault these records as appropriate (e.g., fault 3 and held output if no radiometer temperature). This situation is normal and should clear up in a few seconds.

7-3. FAULT/ERROR IDENTIFICATION.

a. w. Upon identification of a detected fault/error condition in the system, the audible alarm may be silenced and the alarm 3 relay de-energized by depressing the ACK ALARM key. Identification of the fault/error requires access to the diagnostics function (FN15) through the 2nd DIAGNOSE key (paragraph 3-4.m). Depressing the 2nd key followed by the DIAGNOSE key causes a diagnostic code number or an automatically indexed sequence of numbers to appear in the upper display. The fault/error(s) identified by the diagnostic code number(s) may be determined quickly by referring to the Diagnostics Table Label on the inside of the control module door. A more detailed description of the fault/error(s) may be found in Table 7-l.

NOTE

Multiple fault/errors display in numeric sequence of diagnostic code numbers and not necessarily in order of occurrence.

b. Fault Overrides. Under some circumstances, parameters may go into an error condition, often in an intermittent fashion, as a result of other, more important faults. For example, an excessive IR detector output can upset at A/D conversions required to measure temperature. To assist the user in focusing attention on correcting the most important faults first, there are two conditions which sup- press the display of other faults until the primary fault has been corrected.

1. Fault 6 (Communication Failure) suppresses display of all other faults.

2. Fault 5 (Intensity Too High) suppresses display of Faults 1,2,3,4 and 7.

If suppressed faults are present, and if they remain present after the primary fault has been corrected, they will be added to the list of automatically indexed and displayed diagnostic code numbers and cause the audible alarm/alarm 3 combination to activate at that time. After correction of a major fault, a few faulty records may be expected, giving rise to a momentary situation similar to that described in paragraph 7-2.f.

7-4. FAULT/ERROR DESCRIPTION.

Table 7-l provides brief descriptions of the various fault/errors that may be detected by the microprocessor diagnostics program. Although all fault/error conditions require user acknowledgment and subsequent corrective action, certain fault/enors are prioritized as system-disabling.

Fault/errors identified by diagnostic code numbers 2, 3, 5, 6, 7 (if FNO6=256), 13 and 14 are system- disabling. The presence of such a condition in the system invalidates or terminates data essential to a valid CO computation by the microprocessor. For this reason, detection of a system-disabling fault/error condition causes the displayed ppm reading and the analog output signal to be held at the last valid live CO value. Until such time as action has been taken to correct the fault/error condition, the system remains in the held output mode to prevent the processing of invalid data and its transmission to the user’s control system.

7-S. TROUBLESHOOTING.

The descriptions given in Table 7-1 are intended to identify to the user the natures of the various fault/error conditions which are symptomatic of specific operational problems or component failures and suggest possible solutions

Table 7-1. Diagnostic Fault/Error Descriptions (Refer to Footnote 22 in Table 7-6)

DIAG- NOSTIC FAULT/ SYSTEM CODE # ERROR DISABLlh’G DESCRIPTION COMMENTS

1 source No IR source temperature 1. Adjust source temperature temperature (FNOI) is below 9329

(500°C) or above 14729 setpoint (Figure 3-9).

a. (8OO’C).

2 Flue gas Yes Flue gas temperature 1. Cold junction compensation temperature (FNO2) is less than 689

(2O’C) greater than the assures tlue gas temperature measurement accuracy; an ape:

cold junction temperature (FNlO) or above 6629

circuit flue gas - thermocouple

(35OQ will read approximately cold junction temperature. To ensure that this failure generates fault, the lower limit is set above cold junction temperature.

2. This is not a system-disabling fault if in manual flue gas

b. temperature compensation.

3 Radiometer Yes Temperature inside the 1. Radiometer temperature must temperature detector (FN03) is below tube remain within limits for

-229 (-3O’C) or above correct ambient temperature 18S=‘F (85’C). compensation of narrow band-

pass optical filter to ensure c. valid CO computation.

4 Cold junction No Temperature inside the IR 1. Valid flue gas temperature temperature receiver module (IWO) is measurement requires cold

below -229 (-3O’C) or junction compensation. above 185oF (85°C).

2. Taking into account internal temperature rise, this fault indi, cates that receiver ambient tern perature is outside limits prescribed for proper operatior

d.

3. In the event of this fault, the radiometer temperature less 5“C will be used for cold jonc- tion compensation in FNOl am FNo2.

IElM-510A 73

Table 7-1. Diagnostic Fault/Error Descriptions (Refer to Footnote 22 in Table 7-Q (Cont.)

DL4G NOSTIC FAULTI SYSTEM CODE # ERROR DISABLING DESCRIPTION COMMENTS

5 Intensity too Yes Value of CO cell intensity 1. Displays as EEEE. wish (FN04 or FN06) or of

nitrogen cell intensity 2. Adjust RI8 on receiver CPU (FNCi5 or FNOI) is greater board countercloclwise

e. than 8191. (Figure 3-8).

6 Communi- Yes Control module has not 1. Check communications line am cation failure received valid digital power to receiver.

information from the IR receiver module for 10

f. seconds or more.

I Intensity too No Value of CO cell intensity 1. Calcium fluoride window in IR low (FNO6) is less than 2048 receiver is coated.

continuously for a period of two minutes. 2. Hue gas opacity is excessive.

g. 3. IR source is coated.

4. Shift in alignment.

5. Obstruction in optical path.

6. RI8 on receiver CPU board is too far counterclockwise (Figure 3-8).

Yes Value of CO cell intensity 1. Calcium fluoride window port i (FN06) is less than 256. closed.

2. Failed detector.

3. Obstruction io optical path.

8 EEPROM No Error on writing into 1. Recorded data does not agree write error electrically erasable, with intended entry.

programmable, read-only h. memory. 2. If on keyboard [STORE

ENTRY], repeat.

3. Clears on first successful write.

9 Calibration No Calibration gas cell has 1. Set FN29 = 0 to correct. cell in beam been manually inserted

into the optical path i. (FN29 = 1).

15106510A 74

Table 7-1. Diagnostic FaulVError Descriptions (R&r to Footnote 22 in Table 7-6) (Cont.)

DIAO NOSTIC FAULT/ SYSTEM CODE# ERROR DISABLING DESCRIPTION COMMENTS

10 Cal intensity No Value of nitrogen cell 1. Calibration source is open. too low intensity (FNO7) is less

than 2048 during zero 2. Low detector output. ration segment of the

j. call&ration cycle. 3. In the event of fault, remainder of calibration cycle is aborted, and calibration cycle constants are not updated.

4. Clears on successful calibration cycle.

11 Cal intensity No During zero ratio segment 1. Shorted calibration source triac too high of the calibration cycle, on receiver power supply board.

nitrogen cell intensity (FNO7) is overload even 2 In the event of fault, remainder at minimum calibration of calibration cycle is aborted,

k source duty cycle. and calibration cycle constants are not updated.

3. Clears on first successful calibration cycle.

12 CalZero No During dark level segment 1. Dark level segment is not at- offsets too of the calibration cycle, tempted unless it has been at high nitrogen cell intensity least 32 minutes since calibra-

(FNO7) of greater than tion source was last heated. 1. 64 units (25 mV at

receiver CPU TP B+) was 2. In the event of this error, the encountered. dark levels are not updated, and

the remainder of the calibration is aborted.

3. In the event of fault, remainder of calibration cycle is aborted, and calibration cycle constants are not updated.

4. Clears on first successful calibration cycle.

13 Receiver in Yes Receiver CPU align/run 1. Set receiver CPU align/run align mode switch (Sl) in align switch (Sl) to run position.

m. position.

DIAG NOSTIC CODE #

14

Table 7-1. Diagnostic Fault/Error Descriptions (Refer to Footnote 22 in Table 7-Q (Cont.)

FAULT/ SYSTEM ERROR DISABLING DESCRIPTION COMMENTS

Comm OK, Yes but not updating

n.

Control module receiving 1. IR receiver undergoing valid digital data from frequent resets. the IR receiver module, but no new data has 2. Chopper motor stalled or been contained in the last optical switch (speed sensor) 10 valid transmission. failing to sense rotation.

7-6. GENERAL TROUBLESHOOTING OF FAULTS.

Problems in the analyzer can be addressed very simply, if approached in the proper manner. The following procedures and flow charts are designed to assist in the location of the subassembly (major part) that is most likely responsible for the problem.

NOTE

A working knowledge of the principles upon which the Model 5100 operates is helpfoul in allowing the person responsible for repair to be successfol in a minimum amount of time.

The following tables are intended to give service personnel a quick reference to come common problems and solutions to those problems.

Table 7-2 lists symptoms of problems and causes in order of probability. In order to use this aid effectively, the operator must match the symptom to that which is observed. The next column will give a list of causes, the most common first.

Table 7-3 provides the part description and part number of major sub-assemblies. This information is provided along with the symptoms, typically seen, should the assembly fail.

NOTE

Reference letters found in reference column of Table 7-2 refer to assembly descriptions found in Table 7-3.

a. Flow Chart Svmbols. Table 7-4 defines the meaning behind the symbols used in every flow chart. This table alx, shows, under the example, the general location of directions inside inside the action symbols.

b. Flow Chart Abbreviations. Table 7-5 defines abbreviations used in flow charts. The abbreviations sre basically initials for either an action and/or a part name.

c. Flow Chart Footnotes. Table 7-6 provides a reference to subsectio& which will assist in the action recommended in the action symbol.

IB10&51OA 7-6

Table 7-2. Symptoms and Causes

SYMPTOM

Cannot align receiver, LED’s will not ram* up.

Receiver alignment LED’s are not lit

Noisy dark level signal (window closed)

All segments of control module display on at the same time

Control module LCD display garbled

Alarms inoperative

Solenoid(s) won’t energize

Cal cycle won’t come on or go off

Source will not function I

TABLE 7-3 CROSS REFERENCE

A

B

C

D

E

F

G

H

CAUSE IN ORDER OF PROBABfLTlY

1. Window slide in optical path 2. Misalignment Receiver to main source module 3. Detector ground strap loose 4. Defective detector 5. Receiver CPU circuit board defective 6. Dashpot defective causing dual gas cell misalignment

in optical path, i.e., dashpot acting as a stop rather than a shock absorber.

1. Calibration source partially blocking optical path 8. No source output

1. Misalignment receiver to main source module 2. Detector ground ground strap loose 3. Defective Detector 4. Defective receiver CPU board

1. Detector ground strap loose 2. Defective detector

1. Defective control module power board 2. Defective control module CPU board 3. Defective control output circuit board 4. Defective keyboard 5. Defective connector on control module interface

board

1. Defective control module CPU board 2. Defective control output circuit board 3. Defective control module power supply board 4. Defective control module keyboard

1. defective control module power supply board 2. Defective control module CPU board 3. Defective control output circuit board

1. Defective receiver module power supply board 2. Defective receiver module CPU board 3. Defective solenoid

1. Defective control module CPU board 2. Defective output circuit board

1. Defective temperature control circuit board 2. Defective intermediate source subassembly

Table 7-2. Symptoms and Causes (Cant)

SYMPTOM

Incorrect flue gas temperature reading

Overload (of) or consistent negative CO readings

Communication link (connection) problem

IABLE 7-3 CROSS REFERENCE

J

K

L

-

CAUSE IN ORDER OF PROBABILITY

1. Poor thermocouple wire connection to receiver module

2. Flue gas thermocouple broken

1. Defective dash pot 2. Misaligned dual gas cell subassembly 3. Defective chopper motor 4. Set zero function done with high levels of CO in flue

1. Defective wire connection receiver to control module 2. No AC power to receiver 3. Defective receiver module CPU board 4. Defective control module CPU board 5. Defective output circuit board 6. Defective receiver module power supply circuit board

Table 7-3. Parts vs. Possible Pmblem

Subassembly Module Description

Table 7-2 Reference Possible Problem If Defective

Source Module

22883-00 (115 VAC) Source temperature controller 1 A. Full 100% on duty cycle, temperature A above 800°C (fault code 1)

22883sOl(230 VAC) B. No AC Power to intermediate source subassembly (fault code 7)

22947-00/22871-00 Intermediate source

E ~~~~moco”ple 1 A. Fault code 1 (T.C.) A B. (Zero intensity)2 cannot align receiver (fault

code 7) C. Trips ground fault breaker, moisture inside

insulation. Can dry out over time.

J A. Fault code 2 B. Noisy temperature reading (check wire to

receiver)

Receiver Module

22837-00 Receiver CPU circuit G A. Multiple faults 1,2,3,4 and 7 at the same time L B. All operations of the receiver A C. Communication failure, fault code 6 B D. Fault code 4 (cold junction)

E. Fault code 3,5,6,10,11,12,13 and 14

IBlO&SlOA 7-s

Table 7-3. Parts vs. Possible Problem (Cont.)

Subassembly Module Description

22810-00 (115 VAC) Receiver power circuit 22810-Ol(230 VAC)

‘1 I Possible Problem Ip Dekctive

G L

A. One or all of the three radiometer solenoids will not energize.

B. Calibration source will not get hot. (fault code 10)

C. No power to CPU board in receiver- communication. Failure fault code 6.

D. No movement dual gas cells and chopper motor

2286%00/22985-00 Calibration source A. Fault code 10.

22843-01122843-00 Chopper motor K A. Intermittent fault codes B. Extreme variations in temperature readings C. Fault codes 6,14 D. LCD display will not update E. Held output and/or fault code 5 F. Very noisy CO readings

22819-00/22819-01 Detector

22886-00 Dual gas cells

I

Control Module

22820-00 (115 VAC) Control module power D A. Blank upper and lower display screens 22820-01 (230 VAC) F B. No alarm closure. Alarm 1,2 or 3 (open)

E C. Alarm 1,2 or 3 closed all the time (shorted) D. All segments of both displays energized

22827-00 Control module CPU circuit board

D A. Communications failure fault code 6 F B. All segments on displays energized L C. CO readings not correct E D. Address data has changed from data H on the sticker located on the back of the

keyboard.

B C A

K

A. Fault code 5 B. Fault code 7 C. Cannot align receiver D. Fault code 3 E. Very noisy CO readings*

A. Very high CO readings B. Alternately high and low (cell alignment) C. Dashpot damping may need adjusting

22820-00 Output circuit board H A. Current or voltage output inoperative D B. Garbled LCD segments E C. All LCD segments on at the same time

22832-00 (English) Keyboard 22832-01 (German) 22832-02 (French)

D A. Missing segments of displays E B. All segments of displays on

C. Cannot input data to CF’U

*See paragraph 7-6.f

d. More Than One Action in an Action Block. Afier completing each action item, check to se if the problem still exists. If the problem is unresolved, go to the next action in that block. If the problem has been cured, ignore the rest of the actions and go directly to the next decision block in the flow.

Example: We have a fault 2. The action block states:

REPLACE: CCPU COTFT csc

1. Replace control module CPU circuit board (CCPU).

2. Is the problem still there?

Yes: Replace control module output circuit board (COTPT). Is the problem still there?

Yes: Call your nearest ROSEMOUNT service center (CSC). If any of the answers to the above questions are No:

The problem has been solved; go directly to the next decision symbol.

References Made to Addresses in the Memory.

PEEK -- (C001) PEEK -- (OC07)

There are addresses in the memory of the 5100 (Function 60). They are expressed in hexadecimal notation, which is explained in paragraph 3-9.

It has been noticed over a period of time that some of the noise problems associated with 5100 Detector assemblies can be iixed rather easily in the field. Although it will not always solve the problem, it is worth investigating the grounding of the PCB inside the detector tube to ensure good contact is made.

To do this, simply unscrew the back of the detector mbe and inspect the metal to metal contact between the ground strap on the PCB and the brass htbe surmtm~mg the board. This metal tab or ground strap can corrode, or on occasions where there is excessive vibration, it can break or simply lose contact with the sumtm&mg tube. If this happens, improper grounding of the assembly will cause noise interference and the CO reading will tend to be very unsteady.

NOTE

Great care should be taken when unscrewing the detector tube and removing the PCB. Mounted on the front of the PCB is tbe Pyroeledric Detector, which can easily be knocked out of position. A narrow band pass filter is mounted over this with a rubber cover. Both of these are easily dislodged.

7-7. GUIDELINES FOR FAULT CODES.

a. Multiple Faults.

SYMPTOM: Multiple faults displayed in Function 15.

MULTIPLE FAULTS i.e. more than one fault present in the diagnostic function 15 at one time. This condition may be due to those faults coincidentally occuning. The most probable cause, however, is one of the input voltages to the analog to digital converter (U18) on the Receiver CPU hoard (RCPU) is over 4 times receiver test paint 6. The excess voltage will cause a scrambling of the digital outputs. The key to this occurrence is if two or more of the faults are in group: Fault code #l, 2.23.4 and 7.

b. Fault Code 1. (Source Temperature)

FAULT CRITERIA: Idared (IR) source temperature (FNOl) below 932°F (500°C) or above 1472°F (8OO’C).

1. Fault code 1 indication will sometimes be seen with fault code 7 (low intensity). This usually means loss of power to source heating coil (source lntermedlate subassembly).

2. Fault code 1 may also be indicative of a bad thermocouple (TC) in the source or bad interconnecting wire to receiver CPU board.

3. A defective source temperature controller may be seen as runaway temperature above 1472’F (8C@C).

e. Fault Code 2 (Flue Gas Temperature)

FAULT CRITERIA: Flue gas temperature (FN02) is less than 36’F (2O’C) greater than the cold junction temperature (FNIO) or above 662°F (35O’C); or the flue gas thermocouple is open circuit.

1. Gas temperature fault may be generated due to an open thermocouple, broken thermocouple wire or loose wiring comwtions. For a quick check of the overall T.C. system, when fault 2 is displayed, place the instrument in manual gas temperature and recheck the diagnostic statlls. The fault should no longer be displayed.

2. Flue gas temperature can be observed in FN02. If within the above stated limits, thermocOuple is probably good.

d. Fault Code 3 (Radiometer Temperature)

FAULT CRITERIA: Temperature inside detector tube (FN03) is below -22’F (-3O’C) or above 185’F (85%).

Temperature is measured inside the detector tube using a cold junction semiconductor. See Table 8-2, test point 11 on the receiver CPU board.

e. Fault Code 4 (Cold Junction Temperature)

FAULT CRITERIA: Temperature in the IR receiver module is below -22°F (-3O’C) or above 185OF (85°C).

f. Fault Code 5 (Intensity Too High)

FAULT CRITERIA: Value of CO cell intensity (FN04 or FN06) or of nitrogen cell intensity (FN05 or FN07) is greatex than 8191.

Begin troubleshooting fault 5 by checking source receiver alignment and R-18 on the receiver CPU board. This is a quick check if excessive IR intensity is present.

IE1cfA10‘4 7-11

g. Fault Code 6 (Communication Failure)

FAULT CRITERIA: Control module is not receiving valid digital information from IR receiver module. for a period of 10 seconds or more.

A fault 6 indication, if present when cammmi cation link wiring is intact, may indicate electmmag- netic interference. Insure that shielded cabling is used and that communication link conduit does not carry high voltage power liis.

IL Fault Code 7 (Intensity Too Low)

FAULT CRITERIA: Value of CO cell intensity (FNO6) is less than 2.048 for a period of two minutes, of less than 256 for one reading.

1. Ensure that the calcium fluoride window port is open.

2. A low intensity fault displayed with proper source temperature, a clean window and low flue gas opacity may indicate detector problems.

3. Check source to receiver alignment.

4. Check for proper source temperalure.

5. IR source coated.

6. R18 on receiver CPU board is too far counterclockwise.

i. Fault Code 8 (EEPROM Write Error)

FAULT CRITERIA: Data is not being written into EEPROM.

Insure that all boards in the control module are properly seated. Remove power from the system prior to removing and reseating the PCB’s.

NOTE

Removing power from the system will clear the fault until the system attempts to write to the EEPROM again.

j. Fault Code 9 (Calibration Cell in Beam)

FAULT CRITERIA: Calibration gas cell has been manually inserted into the optical path f.FN29 = 1).

This flag does not normally mean that the analyzer is malfunctioning, reminds the operator that the cal cell is in the optical path.

k Fault Code 10 (Cal Intensity Too low)

FAULT CRITERIA: Value of nitrogen cell intensity (FNO7) is less than 2048 during zero ratio segment of the calibration cycle.

1. Ensure blue ribbon connector, power supply PCB to CPU PCB in receiver are properly seated,

2. Ensure cal heater wiring is correct.

1. Fault Code 11 (Cal Intensity Too High)

FAULT CRITERIA: Calibration cycle is terminated by the receiver due to its inability to avoid a TP B+ (test point on receiver CPU board) intensity overload situation even with the minimum posslMe duty cycle (1/32nd).

1. Fault Cleared On: Successful determination of a matching duty cycle during a subsequent cal cycle or a receiver RESET.

2. Likely Cause of Fault: Shorted calibration source triac on receiver power supply card. Also could be caused by a bad detector (e.g., missing ground strap) -but in that case it would likely be accompanied by Fault 5.

m. Fault Code 12 (Cal Zero Offsets Too High)

FAULT CRITERIA: Calibration cycle is terminated by the control module due to excessive dark level intensities.

The dark level test is made only if the cal heater is known by the control module to have been off for at least 32 minutes, and if processed, the levels will be rejected (terminating the cal cycle) if the analog voltages at TP A+, TP A-, TP B+, and/or TP B- (located on receiver CPU board) are more than approximately + 25 mVLK.

1. Fault cleared on: Acceptance of dark level offsets in a subsequent cal cycle or a receiver reset.

2. Likely cause of fault: Failed calibration source solenoid, causing the “dark level” data to be col- lected looking at the main source rather than at the cold calibration source. Also could be caused by a bad detector with a high noise level, or a shorted triac causing the calibration source to be under power continuously.

n. Fault Code 13 (Receiver in Align Mode)

FAULT CRITERIA: Data is received indicating the receiver module is in its alignment mode.

a. Fault Code 14 (Comm O.K. But Not Updating)

FAULT CRlTERLA: There was no new data in the last ten valid transmissions received from the receiver module.

The common cause of this failure is frequent resets due to a defective chopper motor.

E%l%-51OA 7-w

Table 7-4. Flow Chart Symbols

---------- - -----..------ -- FLOW CHART N”MBEwLmER STARTING POINT PLACE TO RE ENTER FLOW CHART.

0 ---------------------- ACTION SYMBOL(WHATT0 DO)

-------------------- DESCRIPTION SYMBOL (INFORMATION)

0 ------------------ DECISION SYMBOL(WHlCH WHICH WAY TO GO)

EXAMPLE

ACTION SYMBOL r

REPLACE: CCPU COTPT csc

le.,lS+22 -

I)-

ABBREVIATION OF PARTS

FLOW CHART FOOTNOTE REFERENCES

NOTE

FOLLOW THE ARROWS:

Table 7-5. Rekrence of Flow Chart Abbreviations

Abbreviation Meaning

? A decision must be made

TP# Test Point (see pertinent schematic)

RCPU

CCPU

Receiver CPU circuit Board

Control Module CPU Circuit Board

COTPT 1 Control Module Output Circuit Board

RPIS 1 Recerver Power Supply Circuit Board

CPIS Control Module Power Supply Circuit Board

C REAR Control Module Rear Interface Board

RCVR 1 Receiver

P# Plug (see pertinent schematic)

J# Receptacle for Plug (#)

CSC

Cal.

Consult service Center

Calibration

Peek Read data in address (FN60)

FN# Functions - Example (FNSO), Reference voltage) (see paragraph 3-6))

T.C. Thermocouple

TB# Terminal strip (see pertinent schematic)

Subassy Subassembly (Major part of 5100)

stop

CTL

Corn

VRMS

Y

I - Stop troubleshooting problem solved

Control Module

Communication

Volts - average voltage A.C. somewhat less than peak voltage, peak to peak voltage = oscilloscope. VRMS = Volt meter on VAC setting.

Yes - direction to follow from decision block

Abbreviation

N

Stk

<

z

Footnote Number

1

2

3

4

5

6

I

8

9

10

11

12

13

14

15

16

17 RECEIVER CPU BOARD Replacement

18

Table 7-5. Reference of Flow Chart Abbreviations (Cont.)

Meaning

No - direction to follow from decision block

Source circuit board stack (temperature control)

Less than the value stated after c sign

Greater than the value stated after > sign

Table 7-6. Flow Chart Footnotes

Description Page No.

List of Rosemount Service Centers (consult factory)

Power Supply Check

SOURCE Removal

SOURCE Removal of Circuit Boards

SOURCE Installation of Circuit Boards

SOURCE Test Procedures/Installation

THERMOCOUPLE Test

RADIOMETER Removal/Installation

DETECTOR Removal/Installation

SPEED SENSOR Test and/or Replacement

DUAL GAS CELL AND CALIBRATION GAS CELL RemovalAnstallatioz 1

CHOPPER MOTOR Removal/Installation

CHOPPER MOTOR Test

CAL SOURCE Removal/Installation

CONTROL MODULE CPU BOARD Replacement

6-7

8-l

8-3

8-4

8-5

8-7

8-11

8-12

8-16

8-17

8-22

s-2.5

8-27

8-28

8-30

IElM-510A 7.16

Table 7-6. Flow Chart Footnotes (Cont.)

FOOtnOte Number

19

20

21

22

23

24

25

26

27

28

29

Description Page No.

OUTF’UT CIRCUIT BOARD Calibration 8-31

REFERENCE VOLTAGE Entry 8-33

RECEIVER ALIGNMENT Procedure 8-34

Limits of Fault Codes (Table 7-l) a. Fault 1 (FNOl) f. Fault 6 k Fault 11 b. Fault 2 (FN02) g. Fault 7 (FN06) 1. Fault 12 c. Fault 3 (FN03) h Fault 8 m. Fault 13 d. Fault 4 (FNlO) i Fault 9 (FN29) n. Fault 14 e. Fault 5 (FNO7) j. Fault 10

Limits on Voltages and Resistances a C Rear 21-23 g. RCPU Pl-7 m. Source Stack TB2-$6 b. RCPU TB3-A,B,COM h. RCPU TP-6 n. Cal Source c. RCPU TB2-1 and 2 i. RPIS TP-1 o. RCVR Base AC d. RCPU Pl-3 j. RF/S TP-2 p. RCPU TPl-4 e. RCPU Pl-5 k. RPIS TP-3 q. RCPU Pl-2 f. RCPU Pl-6 1. RPIS TP-5 r. RCPU P&10, 11, 12

Peek at Address 0000

7-3

7-36

Peek at Address ooOO7 7-31

Peek at Address OOOl,OOOW2

cleaning Calcium Fluoride Window

Consult Operator’s Manual

7-38

8-39

KS-106510A 7.17

Figure 7-1. Multiple Faults Flowchart

IB-l(MSlOA 7.18

I I-

Figure 7-2. Source Temperature Flowchart

ELlC&SlOA 7.19

l NOTE: If FNlO value is not at least 21 degrees Celsius less than FN02 value,fault 2 will appear. This may not indicate a bad flue gas thermocouple. The temperature of the flue gas may be too low with respect to the ambient air in the receiver. If the flue gas temperature can not be increased or the internal receiver temperature can not be decreased, the 5100 must be operated in the manual gas temperature configuration

Figure 7-3. Flue Gas Temperature Elowchart

Figure 7-4. Radiometer Temperature Flowchart

ELlO&SlOA 7-21

Figure 7-5. Cold Junction Temperature !Jkwchart

v - 1 CiSCONMCT “““2 moM,

I

I

c 4

&

Fignre 7-6. Intensity Too High Flowchart

Figure 7-7. Communication LinkFlowchart #l

IBlc&XOA 7-24

Figure 7-S. Communication Link Flowchart #2

Figure 7-9. Intensity Too JAW Flowchart

IB-lM-510A 1.26

0 a

Figure 7-10. EEPROM Write Error Flowchart

IB-lM-510A 7-27

Figure 7-11. Calibration Cell in Beam Flowchart

NOTE: When hold flag disappears, g;;;,ed to next decwon

*Receiver or.c_ontrol mod@? reset, can be initiated by removing and reapplying AC; power to tne moaule.

Figure 7-12. Calibration Source Flowchart

E+lC641OA 7-29

Figure 7-W. Calibration Cycle Aborted by Receiver Unit FIowchart

1BlC.SSIOA 7.30

l FAULT 12 CHECK WILL WORK PROPERLY ONLY AFTER 32 MINUTES FROM THE TERMINATION OF LAST CALIBRATION CYCLE.

* * CYCLE THROUGH ADDRESSES CONTINOUSLY FOR THE FIRST MINUTE OF THE CALIBRATION CYCLE WHILE OBSERVING DATA IN EACH ADDRESS DATA VALUES WILL BE BETWEEN:

m h&i EITHER 0 OR 8

Figure 7-14. Calibration Cycle Aborted by Control Module Flowchart

lE!-10651OA 731

Figure 7-15. Receiver in Alignment Mode Flowchart

IBlO&SlOA 7.32

I -i

I Y

I

Figure 7-16. No New Data Transmitted Flowchart

* NOTE: System reset symptoms can be: A) Dual gas cell not timing evenly

(2.5 second/cell) 6) Chopper motor spinning very rapidly

Frequency at TB5 greater than 40 Hz.

Figure 7-17. System Reset Flowchart

p. Troubleshooting Svstem (Receivers Reset.

1. Under normal operation the only time a system reset will occur is at the initial power up of the receiver. This is done to ensure all components on the receiver CPU board will be starting in the proper sequence.

Under a defect condition, (i.e. when the CPU asks for information from an address that is not there or poor timing causes the CPU to become confused), the watch dog circuit will cause the reset condition.

NOTE

Under reset conditions due to improper timing a fault 14 may occor.

The reset condition, caused by a defect, can be observed exhibiting the following symptoms:

(a) Dual gas cells are not cycling (similar to alignment mode) or the dual gas cells are cycling intermittently (not consistently 2.5 seconds per cell in the optical path).

@) Analog to digital conversions as seen in functions 01, 02, 03 and 10 are not stable. These values are temperatures and should not be changing radically over a short period of time (approximately 30 seconds is average response time for 5°C change in temperature).

2. How to Confirm Receiver Reset Condition.

(a) Observe dual gas cell timing. CO and nitrogen cells should be in the optical path an equal amount of time, 2.5 seconds for each cell. If dual gas cells have stopped this is usually a reset condition.

(b) Observe the analog values on the control module upper display.

FUNCTION 01 FUNCTION 02 FUNCTION 03 FUNCTION 10

NOTE

Dual gas cells not moving may mean a defective solenoid or receiver power supply board, the receiver in the alignment mode or a defective chopper motor.

3. Troubleshooting Sequence.

(a) Using a volt meter with a frequency counter measure test point 5 on the receiver CPU board. This should be 40 Hz*. This is the timing for the entire receiver. If TP 5 is good, go to step (e).

(b) Check to make snre the chopper motor is not hitting the speed sensor. If it is, reposition the chopper motor carefully so as not to damage the motor shaft.

(c) Check wire connections Jl, pins 1,2,12,11,10 and 9 for good wire contact.

IBlC&SlOA 735

Cd)

(e)

(0

With a D.C. current meter in series with the chopper motor check that the current is less than 6 milliamps. If current is greater 6 mA replace the chopper motor.

If all steps to this point are good, replace the receiver SPU board.

If the problem still exists, contact the service center in your area.

* The amplitude at TP 5 (receiver CPU board) also ha.% to be adequate (greater than 2.5 volt D.C.). A low reading may indicate a dirty (optical switch) speed sensor.

7-8. LIMITS ON VOLTAGES AND RESISTANCES.

This sub-section is intended to give the operator some voltage and resistance values that would be seen on a good working unit. As all the possible combinations of voltages would be impractical to monitor, we have selected the major points of interest. It is important to remember that the main function of this section is as a reference to the flow charts.

a. Rear interface PCB control module. Communication link connections, Figure 6-9.

With a DMM set to volts, should read 4.2 VDC, 20.5 VDC across terminals 21 (A) to 30 (reference) with a lesser reading occurring every second.

With a DMM set for DC volts, the voltage should read 0.5 VDC, 20.3 VDC across terminals 22 (B) to 30 (reference) with a high reading occurring every second.

b. RCPU TB3 -- A, B, COMM (same as a)

c. If a thermocouple measuring instrument is available the gas temperature can be measured directly at the terminals TB2-l (+) and TB2-2 (-).

If a thermocouple measuring instrument is not available a DC voltmeter may measure the voltage at TB2-1 and 2. The DVM reading will have to be converted to ‘%PC by using Table 13-S. This temperature reading is not the true temperature. The cold junction temperature (FNlO) must be added onto this for the true temperature reading.

d. RCPU Pl-3 (+). COM (+) - 12.0 VDC, 20.6 VDC

e. RCPU Pl-5 (+), COM (-) 0.0 VDC, +0.05 VDC

f. RCPU Pl-6 (+), COM (-) 12.0 VDC, 50.6 VDC

g. RCPU Pl-7 (+), COM (-) O’C = 2.73V, each 33.8’F/l°C = .OlV -220Fl- 30°C = 2.43V 185”F/ + 85°C = 3.58V

h. RCPU TP6 (+), COM (-) +1.25 VDC, 9.6 VDC

i. RP/S TPl (+), RCPUCOM (-) -12.0 VDC, to.6 VDC

j. RP/S TP2 (+), RCPUCOM (-) -12.0 VDC, kO.6 VDC

k. RP/S TP3 (+), RCPUCOM (-) +5.0 VDC, 20.25 WC

1. RP/S ‘l-P5 (+), RCPUCOM (-) +19.2 VDC, to.9 VDC

m. Stack TE%2-5 and 6 (same as c)

ELVX-51!M 7.36

Resistance across solid yellow wires should be measured with an ohmmeter at 400 ohms for calibration source pat #22868-00. (New heater: 200 ohms for calibration soorce part #22985-00.)

RCVR Base TBl-5 to TBl-3 = 115/230 VAC TBl-5 to TBl-1 = 11.5/230 VAC TBl-3 to TBl-1 = 0 VAC

Receiver CPU test point 14 to receiver common with the chopper motor running at 40 Hz should be +3.0 voc, 20.1 VDC.

Receiver CPU plug Pl pin 2 to receiver common with the voltage should be -5 VDC, 20.25 VDC.

Receiver CPU plug Pl voltage should be: Pin 10 to common = 0.0 VDC, *OS VDC Pin 11 to common = 0.0 VDC, 20.5 VDC Pin 12 to common = 21.2 VDC, +0.2 VDC With the speed sensor connected to the receiver CPU board.

7-9. TO PEEK AT ADDRESS 0000.

a. Call up F+J 60 [6] [O].

b. Press decimal point [.I.

c. You should observe a zero in the upper display and the letters Adr in the lower display.

d. Press the [STORE ENTRYJ key.

a. Ensure cal flag is off. The upper display should switch between:

wL addrel 0000~

7-10. TO PEEK AT ADDRESS 0007.

a. Call FN60 [6] [O].

b. Press decimal point [.I.

c Press 7 [7J

d. Press store [STORE ENTRY].

After 7 l/2 minutes of the cal cycle, the held output and flag should come on and the cal source should drop in the optical path. Address 0007 should be reading:

82XX -This value should be greater than 82.

I510&51oA 7.37

7-11. TO PEEK AT ADDRESSES 0001 AND 0002.

NOTE

When looking at address 0001 you will also be able to observe address 0002 when AD- DRESS 0001 is PEEKED (called up in Fy60).

xx j xx Address 0001 t 1 - Address 0002

a. Call up FN [6] [O].

b. Press the decimal key [.I. Observe address in lower display and address in the upper display. Upper display shows blinking zeros.

c. Press [l] key, then press [STORE ENTRY]. Address 0001 will show in the lower display and the following will be shown in the upper display.

NOTE

The use of the letter X in the following address 0001 guide is intended to indicate a variable hexadecimal digit.

ADDRESS 0001

1. Old data/new data transmission

2. Cal cycle in progress

3. Error, old data, new data

4. Error cal cycle in progress

= 0x/2x

=5x

= 8X/AX

=DX

NOTE

Good display will change back and forth between 2X and OX at one second intervals.

ADDRESS 0002

1. Alig&m switch/run all OK

2. Bad calibration source

3. Calibration cell in optical path

4. Bad cal source and cal cell in path

5. Align/run switch in align

6. Align/run switch in align and cal source bad

7. Align/run switch in align and cal cell in path

8. Align/run switch in align, cal cell in path & source bad

= 00

=20

=40

= 60

= 80

=A0

=co

=EO

lEl(KSlOA 7.38

SECTION VIII. SERVICE AND NORMAL MAINTENANCE

8-l.

8-2.

OVERVIEW. This section describes service and maintenance of the Model 5100 CO Analyzer. Replacement parts referred to are available from Rosemount. Refer to Section 9 for parts numbers and ordering information.

REMOVAL OF SOURCE FROM STACKiDUCT.

NOTE

AC power will not he removed from the heating coil (TBl-4,6) by the removal of Fl fuse. Remove AC power completely from the source before source removal.

a. Turn power (AC voltage) off to the source and check at TEJl-1, 2,3 that power is OFF. TBI-1 = Hot ‘LB 1-2 = Ground

TBl-3 = Neutral

b. Ensure that a cover plate is available to cover the hole that will be left after source removal, Figure 8-1.

Figure 8-1. Hardware Locator Source

IB-106.510A

8-1

Figure 8-2. Intermediate Source Figure 8-3. Temperature Control Circuit Board (Stack)

c. Remove conduit wires from the source (TBZ-5,6fIBl-1,2, 3).

d. Loosen the retaining bolts. Remove all but the bolt at approximately the 12 O’clock position.

e. Using gloves, hold the source f&y at conduit. Remove last bolt. Slide the sowce out of the stack or duct and cover the hole with cover plate. Install and tighten the screws which were used to mount the source on to the cover plate.

NOTE

The 5100 source is divided into two major subassemblies:

1. Intermediate source assembly (Figure 8-2) is a sealed assembly, which is in effect the hot side or radiant side of the source. Intermediate source subassembly is to be repaired by replacement only.

2. Temperature control circuit board stack (Figure 8-3). These circuit boards act as a thermostat for the intermediate soUrce subassembly.

The PCB (printed circuit boards) receive the voltage from the thet’mocouples in the intermediate subassembly and pass one TC output voltage to tbe receiver and use the TC output voltage for temperature control purposes.

8-3. REMOVAL OF PCB FROM SOURCE.

a. Remove tbe source conduit cover and move aside warning flap

NOTE

Pictured in Figure 8-4 is the voltage warning cover and the insulator board used with the temperature control circuit board stack of the source module. Both items should be saved for m-use if printed circuit board stack is replaced.

b. Ensure AC voltage to source is OGG. Using a small, slotted screwdriver, loosen the screws on TBl-1, 2, 3 and remme the three power wires. On the TB2 side, ~cmove the three pairs of thermocouple wires (blocks TBZ-1,2/3, 4/5,6).

c. Take a medium Phillips-head screwdriver and use it to remover the PC board assembly by:

1. Unscrewing the four comer screws (#6-32x 1.88) on the top of the board assembly.

2. Carefully lii the entire PCEI assembly out of the enclosure and allow it to hang on the outside from the ground wire.

il. Using #6 nut driver, remove the ground wire assembly by unscrewing the #6-32 nut with the internal lo&washer from the threaded insert of the enclosure.

NOTE

Keep all hardware for the new board assembly.

e. From the board assembly, remove the four screws hardware and gray plastic wiring label plate to be placed on the new PC board.

Figure 8-4. Voltage Warning Cover and Insulator Board

AREAS FORTHERMAL PASYE COYWUND

Iawl //

/ -Tm3Jll BOARD HEAT SINK

SOURCE PRINTED CIRCUIT BOARD STACK

Figure 8-5. Source Assembly

8-4. INSTALLATION OF PCB ASSEMBLY TO SOURCE.

a.

b.

c.

d.

Using a #6 nut driver, attach the ground wire. to the threaded insert inside the enclosure with the #6-32 nut and an internal lock washer.

Check for compound (P/N 9220124) on the heat sink which is located on the bottom of the PCB assembly (Figure 8-5).

Place the gray plastic wiring cover with #6-32 x 1.88 screws and washers on the PCB assembly with the heat sink facing the bare area on the inside of the enclosure. Slide the assembly into the enclosure.

NOTE

Make sure the white or black tires are routed on the TBl side and the paired TC wires are on the TB2 side.

With a medium Phillips screwdriver, tighten the four #6-32x 1.88 screws into standoffs to secure the board assembly.

e. Using a small slotted screwdriver, attach the white or black wires into TBl and paired TC wires into TB2 per the wiring diagram.

f. Check the fuse. It must be a l/8 amp, slo-blo.

JB-1c!&mA 8-l

S-5. SOURCE TEST PROCEDURE.

a. Coil, OhmicValue Test &x~rceL

1. Remove AC power and measure ohmic value TEil-4, 6 (Figure 8-6). For 115 VAC the value should be 15 ohms. The value for 230 VAC source coil will be approximately 60 ohms.

2. Measure ohmic value from TB1-4,6 to case of source. The ohmic value should be greater than 1 megaohm.

3. If any of the preceding measured values are not correct check for poor wire contacts (ml). If none are observed, replace the Hot Side Source Subassembly (P/N 22947-00 for 115 VAC, 22947-01 for 230 VAC).

b. Overall Source Voltage Test of Thermocouples. Table 8-l is designed to give the operator a ready reference to correct voltage outputs from good working thermocouples (TEi2).

Example:

Table 8-1. Non-Cold Junction Corrected Thermocouple Voltage Outputs

Temp mV Temp mV

932‘T/500°c 20.640 1220’%/66O’C 27.445 9500F/510°c 21.066 1238”F/670°C 27.867 9680F/520°C 21.693 1256”F/680°C 28.288 986”F/530°C 21.919 1275’=F/690°C 28.709 1004w540”c 22.346 1296’%/7OO’C 29.128 1022~/55O”C 22.772 1310w710°c 29.547 1040”F/560°C 23.198 1358”F/720°C 29.965 1058”F/57O%Z 23.624 1346”F/730°C 30.383 1076”F/s80°C 24.050 1364w740°c 30.799 10940F/590°c 24.476 1382?F/750°C 31.214 ll12”P/600°C 24.902 1400?/760°C 31.629 1130’?/61O=‘C 25.327 1418~/77O’C 32.042 1148’=F/620°C 25.751 1436?Y780°C 32.455 1166”F/630°C 26.176 1454w790°c 32.866 1184%%4O”C 26.599 1492??/8OO”C 33.277 1202~/65O”C 27.022

I&106-51OA 8.5

Figure 8-6. Source Temperature Control Wire Points

NOTE

T.C. readings plus the reading in fonction 10 should match, or closely approxhnate fonction 01 reading.

c Function Test (Source).

1. Using thermocouple meter, the temperature readings between 1 and 2, then 3 and 4, should approximately equal to each other. See Table 8-2 for voltage values and test points on the receiver CPU board to test the T.C. without a T.C monitor.

2. Duty Cycle: check to see if power (AC voltage) is going to the heating coil. You will need an AC voltmeter. When the source is at its proper operating point established by R18 (Figure S-6), it will have a duty cycle of roughly 23% on (VAC to heating coil), 75% off (no VAC to heating coil). Duration of cycles are 1 to 2 minutes.

TO RECEIVER

Figure 8-7. Temperature Control to Intermediate Source

IE106-51OA s-6

8-6. INSTALLATION OF SOURCE.

DUTY CYCLES TEST PaI

-t

115OR220VAC

(VOLTAGE INPLW TO lol v S”“RCE’

Figure 8-S. Output to In&mnediate Source

a. Remove cover plate if necessary.

b. Position the source into the duct or stack with drain holes at true vertical and horizontal. Install and tighten screws to secure the source to the stack/duct. Insure J-box is orientated so that circuit boards are positioned as shown in Figure 8-6.

f. Connect the source temperature T.C. wire from the receiver to the source at TB2 (in source): Red to TB2-5 and Yellow to T!3206.

d. Connect AC power to TE%l (source) (Figure 8-6); Hot to TBI-1, Ground to TJ31-2; and Neutral to lBl-3. (10@130/200-260 VAC, 50/60 Hz, 550 watts, nominal 1300 watts, maximum 10 amps.)

e.

f.

g.

Apply power to the source. Observe., with AC volt meter or lamp, the AC voltage output between TEZl-4/6 (Figure 8-8). 8-8).

Check that R18 (Figure 8-6) is approximately at the midpoint of rotation and observe the temperature output of Check that R18 (Figure 8-6) is approximately at the midpoint of rotation and observe the temperature output of source (FN 01). source (FN 01).

Wait about~30 to 40 minutes, then check the temperature again. Readjust Rl8 (Figure 8-6) up or down, as necessary. Wait about~30 to 40 minutes, then check the temperature again. Readjust Rl8 (Figure 8-6) up or down, as necessary. Repeat until the temperature of source is 11 12°F/6000C. Repeat until the temperature of source is 11 12°F/6000C. I I

8-7. THERMOCOUPLE TEST PROCEDURE. The following section outlines two possible ways of checking the operation of the Type K tbennocouples used in the 5100, when a thermocouple monitor is unavailable.

Procedure A: Use of this procedure will allow you to see a direct voltage output from the thermocouple.

Procedure B: Use of this prc+dtue will allow you to take thermocouple operation one step further and observe corrected voltage output from the op-amps on the receiver CPU board.

a. Procedore A.

NOTE

We suggest the use of the Rosemount Model 266 Thermocouple monitor for a quicker, more accurate T.C test.

1. Remove thermocouple (TC) wires from connection to temperature monitor (source) PCB or (receiver) CPU board.

2. Place a digital multimeter @MM), use DC volts lowest range, on the T.C. leads and refer to Table 8-2 for temperature vs. voltage equivalents. The cold junction temperature (FNlO) will have to be added to the temperature in Table 8-2.

If either of the source thermocouples is defective, this will require replacement of the intermediate source subassembly (P/N 22947-01 for 230 VAC) or return to the factory for repair (section 9).

b. Procedure B.

1. Using a digital multimeter, connect the positive lead to the test point of interest; (Figore 8-9), the negative lead to common.

2 Table 8-3, “Temperature vs. Receiver Voltage”, will be used to determine if thermocouple and cold junctions are working. The voltages listed are approximations for reference only.

NOTE

Only after interconnecting wires and receiver CPU board operation have been checked should the following table be used. The test points are as follows: TPS = Source temperature TP9 = Gas temperature TPlO = Cold junction temperature TPll = Radiometer temperature

RECEIVER C.P.U. BOARD -

Figure 8-9. TB-2 Source Test Points

IBIOcGSIOA as

Table S-2. Thermocouple Output vs. Temperature

The following table is intended to give you the uncorrected (cold junction) millivolt output of the type K thermocouple used in the 5100. The first column indicates the temperature and the second column indicates the corresponding millivolt output of the thermocouple.

Temp. mV Deg. C 0

Temp. mV Temp. mV Temp. IIIV Deg. C 0

Temp. mV Deg. C 0 Deg. F 0 Deg. F 0

::i%

::Ei ::?.Z 1.2%

E 1.320

::!2

::Ei 1.370

Temp. Deg. F

0

ii ii

150

:;

:%

t2 270

i%

E 920

E

950

Et

%

::E

::t% 1.040

::Ei 1.070

::%!I

:::3

::B 1.140

::kZ

:::;: 1.190

::2:

::;:i 1.240

::t2

::ZtG 1.290

E

::%t 1.340

::%

E 1.390

i:% 1.42c

::;

IBlM-51OA 8-9

Table 8-3. Temperature vs. Receiver Voltage

TP TEMP. VOLT T.C. LOCATION

TF% *.zw 1.38V l.50”

120Z°Fj6500C 1292°Fp@30C

1.63V

lm°F17500c 1.75v t .R8”

SOURCE

TP9 0.133” 0.22N 0.338v 0.45OV 0.563” 0.675V 0.788v

1.013” 1.12.W xzav 1.3SOV

GAS TEMP.

TplO l.365” 1.465” L555” 1.66sv i.765v

COLD JIJNCI’ION

TFm 32’F/O% 68’FJ20°C

1.365” RADIOMETER 1.465”

1d%/40°c 1565v 140°F/600C 1.665” 176°F/800C 1.765v 21Z°F/100~~ 1.86s”

8-8. REMOVAL/INSTALLATION OF RADIOMETER. Refer to Figures S-10 and 8-l 1

NOTE

The radiometer (optical bench) is the most sensitive and critical component on the Model 5100. AU spacing, including stand offs, detector placement, and tight screws are essential to repeatability, signal to noise ratio, and overall performance.

a. Removal of Radiometer.

1. Remove AC power from the receiver. Unplug the connectors from the RCPU and power supply PC boards.

2. Spread the blue plastic clips on the CPU PC board and disconnect the blue ribbon connector. Unplug radiometer plugs Pl and P2 from circuit board connections Jl and J2.

3. With a long standard screwdriver, unscrew the three black screws holding the radiometer front-plate to the receiver module enclosure. These are captive screws and do not need to be fully removed.

Figure S-10. Radiometer Back Half Figure 8-11. Radiometer Front Half

4. Without toarbing lens and gas cells, carefally slide the radiometer out of the receiver module frame.

b. Installation of Radiometer.

1. Carefully slide the radiometer into the receiver module Frame.

2. Using a long standard screwdriver, secure the three screws into the base of the receiver.

NOTE

The ribbon connector is notched to designate the direction the connector is inserted into the CPU circuit board.

3. Spread the blue plastic clips on the CPU circuit board and attach ribbon cable connector ac cording to direction indicated by the notches on connector.

4. Reconnect radiometer plugs Pl and P4 to circoit board connections Jl and 52. Metal plugs have been installed in the connectors in certain pin receptacles to key connectors. Ensure proper placement of connectors on the correct PC board.

IBlcc-510.4 8.11

8-9. DETECTOR INSTALLATION PROCEDURE.

a Remove the label from the new detector and record the numbers from the lab& These numbers tit, be used to adjust the control module for the new detector.

Address

EF30

EE32

EF2.4

EE36

EE38

Value

DETECTOR SiN

Address Vallle

FNSO

FN51

FN53

FN55

NOTE

FNSO should be left at the same value a~ the old label, unless receiver CPU board has been changed.

b. To access the back of the keyboard, loosen six retaining screws on the control module keyboard and remove (J?igure 8-14).

~~~

i Figure S-14. Control Module Keyboard Detachment

IBlOSlOA 8-U

c. Remove the old label and replace with new. Put the keyboard back on the unit, taking care not to damage the copper grounding strips, and tighten the screws on the keyboard. Keep the old label in the history log at the back of this manual.

d. Install the new detector into the radiometer, inserting until the detector end is flush with the inner radiometer wall (Figure S-15).

I

I Do not allow the detector to protrude too far through the radiometer wall or damage to the chopper motor will occur.

e. Install five detector wires into 31 (Figure 8.25). Reinstall the radiometer into the receiver (paragraph 8-8).

NOTE

The detector must he able to see the hot source in order to proceed further.

f. Apply AC power to the receiver and observe the dual gas cell cycle of 2.5 seconds for the nitrogen cell and 2.5 seconds for the carbon monoxide cell.

g. Go to align-position (align/run switch). Carefully move the detector in and out while monitoring RMS AC voltage at test point 13 on the receiver CPU board for maximum output.

h. Tighten screw A (Figure 8-10)

i. Refer to paragraph 8-23 for alignment/intensity checkout

CHOPPER BLADE

INNER RADIOMETER

WALL

CHOPPER

H DETkTOR

Figure S-15. Correct vs. Incorrect Detector InstaUation

j. At the control module, enter Function 60.

NOTE

The following steps are necessary to enter into system memory factory established operational constants specific to the new detector.

IMPORTANT

Whenever you are in the peek and poke, function (60), record all changes as per your action taken, address and data entered. Improper entries unrecorded for later reference may cause the loss of the program in EEPROM and make return to original values impossible.

k. Press decimal point [.I. You will see a group of digits flashing on the upper display and “Adr” on the lower display.

1. Refer to the new detector label. Enter address EE30, then press [STORE]. You will see current data which is in that address on the upper display, and the address, minus the first digit, in the lower display. Record this address and the data for future reference on the log sheet page of this manual.

m. Press [STORE ENTRY again. Enter the factory code if called for (2400), [STORE ENTRY]. You will then see a flashing “0000” on the upper display and the address in the lower display. This indicates that you may now enter the new data. Refer again to the new detector label. Enter the proper data for the address you are now working with, then press [STORE ENTRY].

n. You may now continue entering data from the detector label. Push [NEXTI two times. This will ad- vance you into the next address sequentially. By pressing the user key two times this will decrement the address.

o. After all data is entered, go back through the addresses which are on the label to make sure the data has been entered correctly.

NOTE

Decimal Point Key [.I --Will scroll the rightmost digit upward 0 through 9, A through F.

User Key -- Will scroll the rightmost digit downward F through A, 9 through 0.

Any number key pressed will move the right most digit one place to the left thus allowing entry of the next digit into the rightmost place.

p. Check to make sure output linearization and gas temperature correction co-efficients located in addresses EEZO through EEZC and EZ4A through EE56 match the proper values for the new detector’s part number (Table 8-4).

q. Enter from address label FN 51, FN 53, FN 55.

r. The 5100 is now ready to go back on-line. Refer to Section 4.

E?-l(MSlOA 8.14

Table 8-4. Output Linearization and Gas Temperature Corrections Coefficients

Detector Part Number 22819-01

Output Gxffieient

Address Data

EE20 0000 EE22 02Al EE24 0160 EE26 411D EE28 3401 EE2A 14F2 EB2c B23F

Temperature Correction

Address Data

EEXA 0000 EE4C EOlD EEXE 4E20 EE50 C5CD EE52 OF68 EF.54 oooo EE56 oooo

If the data in the corresponding address in 5100 memory (FN60) does not match the proper data a shown in Table 8-4 for the detector part number it will be necessary to enter this data into the 51M memory in the same manner as paragraph 8-9, m through p.

S-10. Dark Level Test of Possible Noisv Detector. If the detector is suspected of being the cause of a noisy CO signal use the following procedure

a. Obtain an AC volt meter capabie of reading up to 10 volts (RMS).

b. Connect the volt meter between common and test point (‘IF’) 12 on the receiver CPU circuit board. Set receiver RI8 potentiometer in align position (align/run switch) so that 2nd LED from the top is illuminated.

c Position the slide window subassembly so that infrared radiation (IR) from the main source is blocked from striking the detector.

d. Observe the (RMS) millivolt output at TP12. The reading should be less than 200 millivolts RMS.

e. If TP12 voltage is greater than 200 millivolts (RMS) ensure that the slide window subassembly is in the closed position. Ifit is closed, replace the detector.

*If the slide window subassembly (1, Figure S-42) is closed, the window will be exposed to view in the front exterior of the receiver module.

IB-lO&SlOA 8.15

.-

Figure 8-16. Speed Sensor to Receiver

8-ll.TEST AND REPLACEMENT OF SPEED SENSOR.

a. Sueed Sensor Test.

1. With receiirer module powered, measure voltage between Jl, pins 11 and 12. Voltage shoutd be 1.2 VDC 50.2 voc.

(a) Low output when light from the LED reaches the photo sensor (Figure. 8-16).

(b) High output when the light from the LED is blocked by the chopper motor blade (Figure 8-16).

2. Under normal operation there will be a 5 volt square wave at Jl, between pins 9,lO. If there is a failure in the speed sensor it will cause a continual system reset. The dual gas cells will stop cycling, and the chopper motor will nm much faster than normal.

CABLE CLAMP RETAINING SCREW

Figure 8-17. Radiometer Rearview (Cable Clamp)

,RADlOMETER tTOP VIEW)

2 SPEEDSENSOR RETAININ SCREW

Figure S-18. Speed Sensor Location

1. Remove power from the receiver.

2. Remove the four wires from Jl, pins 9, 10, 11, 12.

3. Loosen the cable clamp retaining screw (Figure X-17),

4. Remove and save the speed sensor retaining screw (Figure S-18).

5. Remove speed sensor (1, Figure 8-18) by carefully sliding the cable through the cable retaining clamp (Figure 8-17). Remove black protective sheath from wires.

e. Installation of Swed Sensor to Radiometer.

1. Install speed sensor (Figure 8-18) on top of the radiometer. Install retaining screw and tighten. Install black protective sheath on wires.

NOTE

Tbe more recent design of radiometer will have the speed sensor supported to the back half of the radiometer using a bracket (P/N 32907~OO), two mounting screws (4-40 x 3.1 st P/N 9600405), and 2 #4 lockwashers sst (P/N 99110410).

2. Route the speed sensor wires through cable clamp (Figure 8-17) and tighten.

3. Install four wires into Jl, pins 9, 10, 11, 1’2 observing the color codes in Figure S-25.

4. Reapply AC power to receiver.

S-12.REMOVAL OF DUAL GAS CELLS WITH SOLENOID.

Due to the criticalnatme of gas cell ali&ment, it is necessary to replace a defective pas cd by repl&b~g the entire gas cell solenoid assembly (P/N 228&00), to insure proper opticaif&using.

1. Phillips Screw 2. Retaining Screw 3. Retaining Nuts

and Washers 4. Dashpot Hub

Retaining Screw 5. Retaining Clamp

Figure 8-19. Radiometer Rearview (Disassembly)

a. Remove the radiometer from the receiver frame (see paragraph 8-S).

b. Remove the four l/4 -20x .750 Phillips screws (1, Figure 8-19).

c.

d.

e.

f.

g.

Separate the two radiometer halves to expose the solenoid faces on which the gas cell arms are mounted.

Remove dash pot lever retaining screw (2, Figure S-19). Disconnect lever from hub (4, Figure 8-21). Remove dash pot hub retaining screws (4, Figure 8-19). Remove hub (4, Figure 8-21).

Loosen the cable clamp (5, Figure 8-19).

Remove the two white wires from J2, pins 53.

Remove two solenoid retaining nuts and washers (3, Figure 8-19) and remove dual gas cell assembly (2, Figure 8-20). Remove the black protective sheath from wires.

1. Radiometer Half 2. Dual Gas Cell

DUAL GAS CELL SOLENOID

Figure 8-20. Part Locator Dual Gas Cell Subassembly

1. Gas Cell Assembly 2. Solenoid Stud 3. Set screw 4. Hub

Figure 8-21. Removal of Dual Gas Cell

8-13.INSTALLATION OF DUAL GAS CELL ASSEMBLY.

a. Install dual gas cell assembly (2, Figure S-20) through radiometer half (1).

b. Install two lockwashers and nuts onto the screw posts (2, Figure 8-21) of the dual gas cell solenoid (use loctite 222).

c. Place hub (4, Figure X-21) on solenoid shaft. Physically position dual gas cell so that gas cell #2 is fully in the optical path between the lens and the detector. Tighten hub retaining screws (3) (loctite 222 do not allow loctite to get on the solenoid shaft).

d. Install the dash pot lever into the slotted hole of hub (4) on the dual gas cell solenoid, replace screw (2, Figure 8-19).

e. Route the solenoid cable through the cable retaining clamp (5, Figure S-19). Tighten clamp screw.

f. Install 4 radiometer section screws (1) and tighten.

g. Install radiometer per instructions paragraph 8-8 in this manual.

NOTE I

After replacement of the dual gas cell subassembly (P/N 22886-00) and/or the calibration gas cell (P/N 22842~OO/Ol) it is necessary to re-initialize the auto-calibration constants in the following manner:

h. Apply AC power to CO analyzer and observe dual gas cell operation. Each cell should be alternately positioned in optical path every 2.5 seconds. Dual gas cell should return to its normal (power off) position quickly enough so as not to interfere with the measuring cycle. If dashpot action is too great or too little, remove dust cap from end of dashpot and adjust the exposed screw. The dual gas cell may interfere with CO measurement if the dashpot setting is set too slow. Remove dust cap from end of dashpot and adjust exposed screw.

i. At the control module keyboard go to Function (FN) 55, press [STORE ENTRY] [0] [STORE ENTRY].

NOTE

If the factory code is requested enter [Z] [4] [0] [0] [STORE ENTRY.

j. Ensure FM1 is zero - ifit is not, go to FN51, press [STORE ENTRY] [0] [STORE ENTRY].

NOTE

If the factory code is required, enter [2] [4] [0] IO].

k Press the [Znd KEY] and [SET ZERO]. During this time a relative zero carbon monoxide level should be ensured by increasing excess air to a level to which a relative zero CO condition exists.

1. When the upper display shows ST0 ?, thus asking if you wish to Store an Entry and you are assured of the zero CO mentioned, then press [STORE ENTRY], then return boiler operation to normal.

tn. Go to FN20, press [STORE ENTRY [l] [STORE ENTRYI. Press [2nd/Next] key. Press [Cal/Off/l] key to start a calibration cycle. Observe that the cal cycle flag is energized. Allow the 5100 to operate,

n.

0.

P.

9,

r.

s.

cycling between calibration cycles, for a period of 72 hours.

NOTE

If user code is required see PN 30 for code number.

Go to FN56 and record the value.

Go to FN.55, press [STORE ENTRYJ, enter data recorded in Step n, then press [STORE ENTRY]. Record this value on the blank detector sticker provided.

NOTE

If factory code is required enter [2] [4] [0] [0] .

Go to FN52 and record the value.

Go to FN51, press [STORE ENTRY], enter data recorded in step p then press [STORE? ENTRY]. Record this value on the blank detector sticker provided.

Go to FN20 and re-enter the desired interval (hours) between auto-calibration cycles (24 hours is recommended).

Ensure all old information (except for that data from FN55 and FN.51 which has been changed) is copied from the old detector sticker to the new sticker and the new sticker is installed to the reverse side of the keyboard.

8-14. REMOVAL OF THE CALIBRATION GAS CELL.

a. Remove AC voltage from receiver.

b. Remove the radiometer from the receiver frame (paragraph 8-8).

e. Remove four U-20 x .750 Phillips screws (1, Figure 8-22) on the front of the radiometer face pictured in FigUre 8-22. Separate radiometer halves

1. Phillips Screw 3. HexNut

d.

e.

I.

Figure S-22. Removal Calibration Gas Cell Subassembly

Remove the two solenoid wires from 52 pins 4 and 5.

Remove two solenoid retaining nuts and washers (3, Pigore 8-22). Remove calibration gas cell assembly from radiometer as pictured in Figure 8-23.

Remove three (3, Figure 8-24) armature retaining strews that hold the arm to the solenoid.

SOLENOID

Figure 8-23. Radiometer Front view

IBlOC-510.4 831

CALIBRATION

FRONT SCREWS SIDE

Figure S-24. Calibration Gas Cell with Solenoid

S-15INSTALLATION OF THE CALIBRATION GAS CELL.

a. Attach the new calibration gas cell arm to the solenoid with the three (3) annatore retaining screws (Figure S-24).

b. Install the solenoid assembly to the radiometer half (Figure 8-23).

e. Pot radiometer plates back together using four l/4-20x Phillips screws (1, Figure 8-2). Add standoffs (Figure 8-22).

d. Install the two solenoid tires to 52 pins 4 and 5.

e. Reinstall radiometer into receiver (paragraph 8-8).

f. Reapply power to the receiver and ensure. that the dual gas cell assembly is going in and out of the optical path smoothly and evenly.

g. Go to paragraph 8-13, perform steps j, k, I, m, p, q, r, and s sequentially for completion of calibration gas cell installation.

S-16.REMOVAL. INSTALLATION OF CHOPPER MOTOR.

a. Removal of Chonoer Motor.

1. Remove the radiometer from the receiver frame tiaragraph 8-S).

2. Loosen detector damp screw (1, Figure S-25) and remove detector (6),

15106SlOA 8-22

CHOPPER MOTOR CLAMP SCREW (2)

DETECTOR CLAMP SCREW (1) I

3.

4.

5.

6.

7.

RETAINER MOUNTING SCREWS (4)

RED, CHOPPER MOTOR 1

ELK, CHOPPER MOTOR

GRN, SPEED SENSOR

BLK. SPEED SENSOR

RED, SPEED SENSOR 12

Jl

Figure S-25. Rearview Radiometer for Chopper Motor Replacement

Remove red and black chopper motor wires from J 1, pins 1 and 2.

Loosen cable clamp (3) and slide the chopper motor cable out.

Loosen chopper motor clamp screw (2).

Remove 2 retainer screws (4).

Carefully lift chopper assembly and detector clamp straight up along the slot, rotating the blade as necessary to clear the optical switch. Remove chopper motor from detector clamp.

b. Installation of Chomwr Motor.

Care must be taken so as not to damage the fragile chopper motor blade and motor shaft.

1. Position the chopper motor in the chopper motor hole of the retainer with the cable toward cable clamp (3).

2. Reinstall retainer (5) with 2 each retainer screws.

3. Run cable through cable clamp (3).

4. Reinstall detector (paragraph 8-9, step d through j of this manual). Tighten screw (1).

5. Install red and black wires from the chopper motor to Jl, red pin 1 and black pin 2.

6. Tighten cable clamp (3).

7. Reinstall radiometer. Refer to paragraph 8-8.

MOTOR & BLADE BLADE

P/N m?4S-o1 (1.94’) (CHOPPER BLADE)

Figure S-26. Chopper Motor

S-17.TEST OF CHOPPER MOTOR.

a. Physically inspect chopper motor blade while motor is spinning. Insure blade is not hitting speed WI- SOT (Figure 8-28).

CHOPPER / MOTOR BLADE

Figure 8-28. Chopper Motor Blade Position

PART NUMBER 22843.01 CHOPPER MOTOR.

PPH SCR

4-4ox.31 CHOPPER MOTOR WITH BLADE E mAMETER 1.95in. (49.5 mm)

4.40 HM SM PATT

DUAL GAS CELL W/SOLENOID

Figure 8-29. Chopper Motor

IB1!?&510A %vl

I BLACK

- TP 14

Figure S-30. Chopper Motor Test Set-Up

b. Remove red wire from Jl pin 1 and place a current meter (DC amps) in series between test point 14 on the receiver CPU board and the red wire (Figure 8-30).

Reading should be 2 milliamps. If above 4 milliamps, motor is marginal and a timing problem may exist, replace motor.

8-18. REMOVAI,‘INSTALLATION OF THE CALIBRATION SOURCE.

a. Removal of the Calibration Source.

1. Remove the AC power from the receiver.

2. Remove the radiometer from the receiver frame (paragraph 8-S).

3. Remove the four wires of the cal source from pins 8,9,10, 11, of J2 and pull wires through the cable clamp (Figure 8-31).

NOTE

The two yellow wires have no polarity and can be installed in plug J2 at either position 10 or 11.

4. Remove three #4 Phillips screws that hold the cal source to the solenoid and remove cal source. Remove black protective sheathing from wires.

‘ 52 RECEIVER PLUG

* NEW STYLE CERAMIC CAL SOURCE

I3 Ed El El - J2

RED CAL SOURCE T.C.

YELLOW CAL SOURCE T.C.

YELLOW HEATER ELEMENT

YELLOW I CAL SOURCE

NO CONNECTION

Figure S-31. Subassembly Locator Receiver (Reference)

b. Installation of the Calibration Source.

1. Place cal source (Figure 8-31) over the mounting holes on the solenoid and install the three mounting screws. Install black protective sheathing onto wires.

NOTE

Ensure the protective sheathing does not touch the housing of the solenoid as this may interfere with the solenoid’s operation.

2. Run the cal source wires through the holes in the bottom of the radiometer base and through cable clamp to plug 52.

3. Refer to Figure 8-31 for proper wiring connections to plug 52.

4. Reinstall the radiometer (paragraph 8-S).

IEl(MSlOA 8-26

S-19.RECEIVER CPU BOARD REPJ.AC!BMENT.

a. Remove AC power from the receiver module.

b. Remove connectors Jl and 54 from the CPU board (Figure 8-32). Remove TC wire and communication wire connections from PCB.

LINK

Ji iC WIRE MNNECTIONS

Figure S-32. .WJl Locator

c Remove the four retaining screws.

d. Slide the CPU board out of the receiver frame.

e. Mount the new CPU board on the stand-offs provided. Ensure all mounting screws are in place.

f. Connect Pl to Jl and P4 to J4 of the new receiver CPU boxd. Reinstall TC and Corn. Link wires to CPU board.

g. Apply AC power to the receiver and measure the DC voltage at test point 6 on the receiver CPU board. Enter this value into function 50 on control module and record the value on the address tag (paragraph 8-22).

h. Set Align/Run switch to the align position. Adjust R18 for illumination of the second LED from top. Set the Align/Run switch to Ron (Figure 8-40).

S-20. CONTROL MODULE CPU BOARD REPLACEMENT.

a. Remove AC power from the control module.

b. Loosen the six captive screws on the control keyboard (Figure 8-34). Carefully remove the keyboard. (The keyboard is connected to the CPU board with a ribbon cable.)

Figure S-34. Control Key Board Removal

1510651oA s-28

POWER SUPPLY BOARD

OUTPUT BOARD

CPU BOARD

REAR INTERFACE PC BOARD

(RS-232 OPTIONAL)

Figure 8-35. Control Module Circuit Locator

c. Remove the CPU board (Figure 8-35) by pulling firmly toward you with the pull ring.

NOTE

Do not use components on the board for leverage.

d. Unplug the keyboard cable from the control module CPU board.

e. Connect the ribbon cable from the keyboard to the new CPU board

f. Install the new CPU board into the frame of the control module in the premarked location. Record data from sticker label on the back of the keyboard.

g. Replace the keyboard and tighten the four captive retaining screws.

h. Reapply AC voltage to the control module and enter data from label mentioned in step fusing peek and poke function 60.

i. Follow the instructions in paragraph 8-9, steps j through I, to enter the receiver detector output and temperature coefficients into the replacement CPU board.

S-21. CALIBRATION OF CONTROL MODULE OUTPUT CARD.

a. Press [2nd KEY]; press [RANGE]; press [STORE ENTRY.

b. If user code is called-for enter [S] [l] [0] [0], press [STORE ENTRY]. A “0” will flash in the upper display.

c Enter [l] [0] [O]; press [STORE ENTRY].

d. Enter FN22; press [STORE ENTRY] (0 will flash in the upper display). Press [STORE ENTRY].

e. Press the [CO key] to clear to a CO reading.

f. Press the [STORE ENTRY] key. A flashing zero should be observed in the upper display and two zeros in the lower display.

g. Press the [l] and [0] keys. With the number 10 flashing in the upper display, press the [STORE ENTRY] key. The test value flag should be energized at this time.

h. Connect DMM to V+ and V- (J9 terminals 1 and 2 at rear of control module) (Figure 8-36).

Figure 8-36. Voltmeter to Control Voltage Output Rear Interface Board

i. Adjust R16 on the control module output board for 500 mV (Figure 8-37).

j. Press [STORE ENTRyl (flashing 0 appears in upper display). Enter [l] [0] [O]; press [STORE ENTRY].

k Adjust R14 on the control module output board to 5.00 VIK~O.01 VDC.

1. Press [STORE ENTRY enter [2] 151; press [STORE ENTRY]. Voltage output should be 1.25 VDC, 20.02 WC.

m. Press [STORE ENTRY] enter [5] [O]; press [STORE ENTRY]. Voltage should be 2.5 WC, iO.02 WC.

Figure S-37. Control Module Output Circuit Board

n. Press [STORE ENTRYI; enter [7] [5]; press [STORE ENTRY]. Voltage outputs should be 3.75 VDC, 9.02 VDC. Remove DMM from V+ and V-.

o. Connect DMM to I+ and I- (58 terminals 2 and 1 at rear of control module). Set DMM to read up to 20 milkimps.

p. Press [STORE ENTRY; enter [l] [0] [0], press [STORE ENTRY]. Adjust Rll on the output board for 20.0 mA, kO.02 mA.

q. Press [STORE ENTRY]; enter [l] [0], press [STORE ENTRY]. Output should be 2.0 mA, +0.02 mA.

r. Press [STORE ENTRY; enter [2] [5], press [STORE ENTRY]. Output should be 5.00 mA, kO.05 mA.

s. Press [STORE ENTRY; enter [5l [O]; press [STORE ENTRY]. Output should be 10.0 mA, 20.1 mA.

t. Press [STORE ENTRY]; enter [7] [5]; press [STORE ENTRY]. Output should be 15.0 mA, ~0.15 mA.

NOTE

If any of the steps i through t fail, replace the output board.

u. Press [2nd KEY]; press ~OLD/OFFl. Normal operation of the system should now take place. Hold flag off and test value flag off.

v. Return range and output mode (PN22) to desired values.

Figure 8-38. Current Meter to Control Module Output

8-22. REFERENCE VOLTAGE ADJUSTMENT.

a. Go to receiver CPU board OFirmre S-39). Attach a dieital voltmeter from common to test point 6. Record the DC value in milli;olk ’

. . . . . . . :

‘d-1 .= : 2 EEa Ea

Figure 8-39. Voltmeter to TP6 (Reference Voltage) Receiver

b. Return to the control module and access FN.50. Press [STORE ENTRY]. A security code is required. The factory code to be entered is [2] [4] [0] [O]; [STORE. ENTRY]. You will then see a 50 in the fimction display and a “0” flashing in the reading display.

c. Enter the reference voltage as recorded from step a in millivolts [STORE ENTRY]; press CO. The reference voltage is now set.

NOTE

For the full startup procedure see Section 4.

I&106-51OA s-32

8-23. RECEIVER ALIGNMENT PROCEDURE.

a. Aooh Power to the Infrared Source Module.

NOTE

The IR source will take up to 45 minutes to reach its full operating temperature. When at operating temperature, the radiating surface of the IR source will be seen to glow faintly red when viewed in a darkened room or across the duct or stack.

1. Check the window assembly on the IR receiver module to be sure the window is clean and the slide assembly is in the unobstructed position and folly slid in.

2. Remove the rear cover from the IR receiver module.

3. Check that the printed circuit boards are folly seated and secured, that the fuses are installed and all four cable connectors are secure.

4. Turn the power on to the receiver, with the ALIGN/RUN switch (Sl) on the CPU board in the RUN position (Figure 8-40). The dual cell should actuate every 2-l/2 seconds.

b. Optical Alignment. The radiating surface of the IR source is approximately 4” (10 cm) diameter, and must be viewed by the receiver module. In longer path length applications, careful optical alignment is needed.

1. Set the intensity adjust pot (R18) of the receiver CPU board (Figure S-40) to its full clockwise position.

1718 INTENSITY ADJUSTMENT

Figure 8-40. Receiver Alignment Adjustment Locator

IB-1M.SlOA 8.33

2. Loosen the four securing nuts of the receiver alignment flange to allow the area “seen” by the receiver to be adjusted.

3. Set the ALIGN/RUN switch on the CPU board to the “ALIGN” position. This deactivates the dual cell solenoid.

4. Observe the colmnn of LED’s indicating intensity level, and move the receiver in both the horizontal and vertical planes until the receiver “sees” the source (indicated by sequential illumination of individual LED’s up the column). An audible signal is also activated that provides a corresponding pitch for each LED indicator. If surrounding conditions render the LED’s and audible signals unusable, the EXT METER terminals are available for driving a voltmeter, O-2.5 VDC. Partially tighten the nuts which secure the flange. Reduce the INTENSITY ADJ setting so that the indicator is on scale and then finely adjust the receiver position to maximize the signal indicator. If necessary, reduce the INTENSITY ADJ setting so that the indicator is at the second LED from the top, or the voltmeter reads 1.80 - 1.90 VDC, and repeat this procedure until the optical alignment is optimized and the flange-securing nuts are tightened.

5. Return the ALIGN/RUN switch to the RUN position and replace cover.

8-24. BOARD REPLACEMENT.

Mechanical removal and installation of the control module power supply circuit board, control module output board, control module rear interface board, receiver power supply board and receiver ribbon cable.

a. Removal and Installation of Control Module Power SUDDIV Board.

1. Remove AC power from control module.

2. Loosen the six captive keyboard mounting screws (7, Figure 8-45) and move keyboard (1) clear of chassis.

NOTE

It is not necessary to unplug keyboard from control module CPU board.

3. Locate the control power supply PCB (3, Figure 8-45) at rightmost position of chassis. By pulling removal ring, located near fuse Fl, slide the PCB free from the chassis.

4. Insure AC power to control module is off.

5. Locate power supply circuit board (3) mounting grooves in chassis of the control module.

6. Slide power supply board into control module chassis with electronic components positioned away from other circuit boards (Figure S-45).

7. Reinstall the keyboard to chassis taking care not to pinch flex cable connecting keyboard to the CPU board and take care not to damage the copper grounding strips.

8. Reapply AC power to control module.

15106510A 8.34

b. Removal and Installation of the Control Module Out& Circuit Board.

1.

2.

Remove AC power from the control module.

Loosen the six captive mounting szrews (7, Figure 8-4.5) on the keyboard (1) and move keyboard free from the control module chassis.

NOTE

It is not necessary to unplug keyboard from the CPU board.

3. Locate the output circuit board (5). The board is located between the CPU and power supply boards. Grasp the pull ring located on the closest edge of the board and pull the board free from chassis.

4.

5.

Ensure AC power is removed from control module.

Locate output board mounting grooves in the control module chassis. Position output board (5) into mounting grooves with connector edge of output board pointing toward corresponding rear interface connector (4).

6. Push output board into chassis until its connector is fully seated into connector of rear interface board.

I. Reinstall the keyboard (1) to chassis of control module and take care not to damage the copper grounding strips.

8. Reinstall AC power to the control module.

e. Removal and Installation of Control Module Rear Interface Circuit Board.

1. Remove AC power hm control module and remove the rear cover plate from chassis of the control module by removing the six mounting screws.

2. Remove keyboard and all plug-in circuit boards from the control module (see paragraph 8-24 a and b).

NOTE

Do not unplug keyboard from CPU board.

3. Mark and remove all wire connections from terminal strips and remove green wire connection (chassis ground) from the chassis.

Chassis ground wire is removed by loosening and removing nut, lock washer and screw that hold the wire ring lug to the chassis. Save the screws, lockwasher and nut for the installation procedure.

IB-106-51OA 83.5

4. Remove the six mounting screws at corners of rear interface board which hold the board to the chassis.

NOTE

Do not remove inner mounting screws as this will separate the PCB connection board from the wire interface board.

5. Remove rear interface board from chassis.

6. Remove the 4 mounting screws that secure the nomenclature plate to the rear interface board. Save plate and mounting hardware for the installation procedure.

7. Install the nomenclature plate to the new rear interface board, as shown in Figure 8-36, using mounting hardware saved from the old board removal.

NOTE

Insure spacer washers (plastic) are installed between the rear interface board and nomenclature plate.

8. Position rear interface board into the back of the control module chassis from the back of the chassis and secure to the chassis with 4 mounting screws.

NOTE

When installing the rear interface PCB insure that the board is orientated in the chassis with the plug-in circuit board connection positioned toward the inside of the chassis and, viewing from the rear of the chassis, that the AC power connections are on the left as shown in Figure 8-38.

9. Install green ground wire to chassis ground screw by positioning the screw (6-32 x .31) through small chassis hole near conduit opening for AC power wire with threaded portion of screw protruding into the chassis. Place green ground wire ring lug over the ground screw then place the #6 lock washer over the ring lug. Install retaining nut (#6 x 32) on to screw and tighten securely.

With an ohmmeter insure that the chassis is at earth ground potential with respect to the earth ground power connection on rear interface board.

10. Install printed circuit boards into control module chassis (paragraph 8-20, steps e through h, paragraph 8-24.a., steps 6 through 8, and paragraph 8-24.b., steps 5 through 8).

NOTE

It is very important to insure PC boards are completely seated into rear interface connections. If there is a problem seating these connections loosen tbe 4 rear interface board chassis retaining screws so that the rear interface board will move slightly. Owe control module boards are folly seated retighten 4 retaining screws.

IES-lC&SlOA 8-36

11. Insure keyboard ribbon cable is installed to PS connector of CPU board of the control module. Secure keyboard to chassis with 4 captive retaining screws on keyboard.

12. Reconnect wiring (previously marked as to location) to rear interface circuit board. Double check all wires for good connection (Figure 2-9).

13. Reapply AC power to the control module. Check control module for proper operation by going through all active functions and verifying proper readout with respect to previous values.

14. Reinstall control module rear cover plate.

d. Removal and Installation of Receiver Power Supple Circuit Board (PCB).

1.

2.

Remove AC power from receiver.

Remove 53 end of ribbon cable from P3 receptacle on receiver power supply PCB (paragraph 8-24.e).

3.

4.

Unplug 52 from receptacle P2 on receiver power supply PCB.

Unscrew the captive knurled retaining screw until it is disengaged from the receiver chassis. Screw is located at the corner of transformer ‘I2 on receiver power supply PCB.

5.

6.

Slide power PCB free from chassis.

Position receiver power supply PCB in the innermost mounting grooves of chassis with etch cou- nections pointing toward chassis power connector located on front section of chassis and the electronics components of receiver power PCB positioned away from the chassis.

1.

8.

Slide receiver power PCB into chassis mounting grooves toward power connector until the etch connectors on PCB are fully seated into chassis power connector.

Secure PCB to chassis by tightening the captive knurled PCB retaining screw located at corner of transformer T2.

9. Install ribbon cable connection J3 to connector P3 on PCB.

10. Install plug J2 to receptacle P2 on PCB.

11. Apply AC power to receiver.

e. Removal and Installation of the Receiver Ribbon Cable.

1. Ensure AC power is removed from the receiver.

2. Locate the ribbon cable on the receiver which interconnects the receiver CPU board connector P4 to the receiver power supply board connector P3.

3. Dislodge ribbon cable connector from both P4 and P3 by applying pressure to both connector release levers, located at the ends of P4 and P3, while pulling the cable connection in the opposite direction, free from the board connector.

IB-l&5-51OA 8-37

4. Locate connectors P4 on the receiver CPU board and P3 on the receiver power supply board.

NOTE

The ribbon cable connectors that correspond to P4 and P3 are keyed to fit only one way to iosure proper circuit board interface.

5. Install ribbon cable connectors in to P4 and P3 by applying pressure to ribbon cable connector until that connector fully seats.

6. Ensure both ends of the ribbon cable are connected to P4 and P3. Reapply AC power to receiver,

S-25. CLEANING OF CALCIUM FLUORIDE WINDOW.

a. Remove window (13, Figure 8-42) from receiver. Blow off any dust and rinse window under running water.

b. Clean crystal surface with a soft cloth and a mild diluted detergent or organic solvent such as MEK.

c. Rinse and dry thoroughly.

NOTE

Remember, water will also absorb infrared radiation and case window etchiig over an extended period of time. Ensure that the window is completely dried.

d. Inspect window for scratches or poor cleaning.

NOTE

A scratched window will probably be usable. If a problem with receiver intensity or alignment still exists, replace the window.

e. Reinstall window in receiver.

f. Check purge air filter (3) for material that may block air flow

Use air to blow loose material from filter. If filter still restricts air flow on to window due to a dirty condition, replace filter.

NOTE

If you are using air pressure to overcome a positive stack pressure, check the source of pressure for proper filtration. Check also that the air is dry.

8-26. RECORD KEEPING.

Spot-check and periodically log temperature readings from functions 01.02, and 03 and intensities in functions 06 and 07 to insure that they are all within specifications and stable.

8-27. MANUAG CHECK OF SPAN RESPONSE.

This procedure is intended to manually verify the repeatability of 5100 span response to carbon monoxide. It is not intended to provide a gauge as to the accuracy of measurement. The procedure does however have value as a troubleshooting tool when investigating span cell integrity and overall system sensitivity to carbon monoxide.

a. Increase excess air to a level in the boiler that will insure a relative zero CO reading. Manually initiate a held output at the control module.

b. Set path length (FN24) to 2 meters (6.56 feet).

c Set manual gas temperature (FN27) to 23°C (730F) and observe that the manual gas temperatire flag is energized.

d. Allow CO (FNO8) to stabilize and note reading,

e. Set FN29 to 1 (cal. cell in). The fault flag is energized (fault 9).

f. Allow CO (FNOS) reading to stabilize.

g. reading should be between 5ooO to 7000 ppm plus the CO value observed in step d.

Fxample: (Step g value) - (Step d value) = 5000 to 7000 ppm

h. Return gas temperature to auto (FN27 = 0), manual gas Bag off. Remove the span cell from the optical path (FN29 = 0), fault flag off, return function 24 to the correct path length and turn hold output off. Return the boiler to the proper 0, operating level.

S-28. HISTORY LOG

DATE EVENT ACTION OPERATOR

IB-10651OA s-39

1. Gasket 2. IR Source Intermediate 3. Conduit Nimle 4. Enclosure I- 5. Electronics Unit 6. Fuse (0.125A) 7. Insulator 8. Warning Label 9. cover

/

‘._ 6 ._

‘._ .._

‘_

Figure 8-41. Infrared Source Module, Exploded View

1. cover 6. Flange (4 inch, 150 lb) 2. JetPump 7. Flat Washer, S/S In. 3. Purge Air Filter 8. Split Lo&washer, S/8 In. 4. Washer 9. Hex Nut, 5/S-11 5. Gasket 10. Bolt, 5/8-11x 2.5 In.

11. Split Lo&washer, 3/S In. 12. Hex Nut, 318-16 13. Slide Window Assembly 14. Flange

Figure S-42. Infrared Receiver Module, Exploded View

B-1C”XlOA 841

1. Cable, Ribbon 2. CPU 3. Radiometer 4. Power Supply Card 5. Fuse,2Amp 6. Pose, 1 Amp

F&m S-43. J.nfrared Receiver Module

1. screw, 4-40 x 031 Ill. I. Solenoid, Rotary l2. Dashpot 2. Lo&washer, Int., No. 4 8. Lens l3. Detector 3. Bracket 9. O-Ring 14. Lever 4. Chopper Motor 10. Retaining Ring 15. Dual Gas Cell with Solenoid 5. Hex Nut, 4-40 11. Cahkation Source 16. optical Switch 6. Calibration Gas Cell

Figure S-44. Radiometer, Exploded View

1. Display Keyboard 2. Power Supply Board 3. Output Board 4. CPUBoard 5. Mounting Screws

1

Figure g-45. Control Module, Exploded View

THERMOCOUPLE

3/4’ APT CONDUIT

CONNECTION

Figure S-46. Gas Temperature Probe

IBIC&SlOA 843

WRE --mu-f-

Figure S-47. Subassembly, Electronics Main Source Temperature Control

15106510.4 8d-l

n

Figure S-48. Subassembly, Lower Circuit Card Main Source Temperature Control

SECTION IX. REPLACEMENT PARTS

Table 9-1. Recommended Spare Parts Customer Stocking

INDEX AND FIGURE NO. PART NO. DESCRIPTION QTY.

6, 8-43 9100106’ FUSE, RECEIVER, 14/3AG/250V, llY230VAC 2 5, 8-43 9100142 FUSE, RECEIVER, 2Al3AGl250V; SLO-BLO, 115/23OVAC 2 2, 8-45 9100101 FUSE, CONTROL MODULE, 0.25A, SLO-BLO, 115VAC 2 2, 8-45 9100132 FUSE, CONTROL MODULE, O,125A, 25OV, SLO-BLO, 230VAC 2 6, 8-41 9100132 FUSE, SOURCE, 0.125A. 25OV, SLO-BLO, 115/230VAC 2 1, 8-41 32765.00 GASKET, SOURCE 1 5, 8-42 9090101 GASKET, 4”, 150LB., FULL FACE 1 3, 8-42 9160324 FILTER, PURGE AIR (JET PUMP) 1

9884A16H03 FILTER, PURGE AIR (BLOWER) 1 8-46 8950075 THERMOCOUPLE, FLUE GAS 1 4, 8-44 22843.01’ CHOPPER MOTOR WITH BLADE-BLADE DIAMETER 1

1.95 in. (49.5 mm) Order Kit 22843.03

‘Early models of the analyzer require a 0.5A fuse for 230VAC configurations. Fuse size is indicated on the fuse bolder (see Figure 8-45). If the 0.5A fuse is required, order Part No. 910094, Fuse, Receiver, 0,5A/3AG/25OV, 230VAC.

?be chopper motor with blade is included among those parts recommended for customer stocking. Depending upon conditions, such as the severity of the operation environment and vibration, the operation life of the chopper motor will vary and may be reduced to less than one year. Should failure occur within one year from the date of analyzer shipment, the item will be replaced in accordance with the terms of the standard warranty of Rosemount Analytical, Inc. However, customer stocking is recommended to minimize inconvenience and downtime.

--“-_ .--- _ I____ -_.- ___ ..__ _-_._-_- --..__--_-

INDEX AND FIGURE NO. PART NO. DESCRIPTION QTY.

3, 8-43 22837.00 PCB, CPU RECEIVER Order Kit 22837-01 1 4,8-43 22810.00 PCB, POWER SUPPLY, RECEIVER, 115VAC 1 4, 8-43 22810.01 PCB, POWER SUPPLY, RECEIVER, 230VAC 1 1, 8-35 22827.01 KIT, PCB, CPU, CONTROL MODULE 1 2, 8-35 22828.01 KIT, PCB, OUTPUT, CONTROL MODULE 1 3.8-35 22820.00 PCB, POWER SUPPLY, CONTROL MODULE, 115VAC 1 3, 8-35 22820.01 PCB, POWER SUPPLY, CONTROL MODULE, 230VAC 1 1, 8-45 lNO4975GOl PCB, KEYBOARD/DISPLAY, CONTROL MODULE, ENGLISH 1 1, 8-45 lNO4975G03 PCB, KEYBOARD/DISPLAY, CONTROL MODULE, ITALIAN 1 1,8-45 lNO4975G02 PCB, KEYBOARD/DISPLAY, CONTROL MODULE, FRENCH 1 4.8-35 lNO4976GOl REAR INTERFACE, CONTROL MODULE 1 4,8-35 lNO4976G02 REAR INTERFACE, RS-232, CONTROL MODULE 1 8-47 22883-00 ELECTRONICS UNIT, TEMP CONTROL, SOURCE, 115VAC 1 8-47 22883-01 ELECTRONICS UNIT, TEMP CONTROL, SOURCE, 230VAC 1 15, 8-44 lM03330GOl ASSEMBLY, SOLENOIDlDUAL GAS CELL 1 13, 8-44 22819-01 DETECTOR Order Kit 22819.02 1 16,8-44 9060014 SWITCH, OPTICAL 1 12, 8.44 9395009 DASHPOT 1 11, 8.44 22985.00 SOURCE, CALIBRATION 1

Table 9-3. Replacement Parts for Infrared Source Module

INDEX AND FIGURE NO. PART NO. DESCRIPTION

6, 8-41 9100132 FUSE, SOURCE, 0.125A, 25OV, SLO-BLO, 115/230VAC 1, 8.41 32765.00 GASKET, SOURCE 5, 8-41 22883.00 ELECTRONICS UNIT, TEMP CONTROL, SOURCE, 115VAC 5, X-41 22883.01 ELECTRONICS UNIT, TEMP CONTROL, SOURCE, 230VAC 2, 8-41 22947.00 ASSEMBLY, IR SOURCE INTERMEDIATE, 115VAC 2, X-41 22947.01 ASSEMBLY, IR SOURCE INTERMEDIATE, 230VAC

Table 9-4. Replacement Parts for Infrared Receiver Module

INDEX AND FIGURE NO

5, 8-42 3, 8-42

13,8-42 13, S-42 S/10, X-42 6.8-43 5,8-43 3,8-43 4,8-43 4, 8-43 1, 8-43 8, 8-44 11, 8-44 4, 8-44

9090101 9160324 9884A16H03 9884AlSHOl

4511C83HOl 22838.01 32657-00 22870-00 9100106 9100142 22837.00 22810-00 22810.01 22863.00 32551.00 22985.00 lM03330G02

41158.44 lM03330G03

15,8-44 lM03330GOl 7, 8-44 9180008 6,8-44 22842.01 12, 8-44 9395000 16, S-44 9060014 13, 8-44 22819-01

PART NO. DESCRIPTION

GASKET, 4”, 150 LB., FULL FACE FILTER, PURGE AIR (JET PUMP) FILTER, PURGE AIR (BLOWER) HOSE, PURGE AIR (BLOWER) BLOWER, PURGE AIR ASSEMBLY, SLIDE WINDOW SLIDER PORT (ATTACHED TO SLIDE WINDOW) KIT, FLANGE HARDWARE FUSE, RECEIVER, 1 Al3AG/250V, 115/230VAC FUSE, RECEIVER, 2Al3AG/250V, SLO-BLO, 1 lSl230VAC PCB, CPU, RECEIVER Order Kit 22837.01 PCB, POWER SUPPLY, RECEIVER, 115VAC PCB, POWER SUPPLY RECEIVER, 230VAC CABLE, RIBBON LENS SOURCE, CALIBRATION CHOPPER MOTOR WITH BLADE-BLADE DIAMETER

1.95 in. (49.5 mm) Order Kit 22843.03 CHOPPER MOTOR WITH BLADE-BLADE DIAMETER

1.95 in. (49.5 mm) PLUS SOLENOIDAXJAL GAS CELL ASSEMBLY ASSEMBLY, SOLENOID/DUAL GAS CELL Order Kit 22886.01 SOLENOID, ROTARY CALIBRATION GAS CELL Order Kit 22842.02 DASHPOT SWITCH, OPTICAL (SPEED SENSOR) DETECTOR (LATER MODEL) Order Kit 22819.02

Table 9-5. Replacement Parts for Control Module

INDEX AND FIGURE NO. PART NO. DESCRIPTION

2,x-45 9100101 FUSE, CONTROL MODULE, 0.2SA, SLO-BLO, 11SVAC 2,x-45 9100132 FUSE, CONTROL MODULE, O.l25A, 25OV, SLO-BLO, 230VAC 1, 8-35 22827-00 PCB, CPU, CONTROL MODULE Order Kit 22827.01 2,8-35 22828-00 PCB, OUTF’UT CONTROL MODULE Order Kit 22828.01 3.8-35 22820.00 PCB, POWER SUPPLY, CONTROL MODULE, 1 ISVAC 3,8-35 22820-01 PCB, POWER SUPPLY, CONTROL MODULE, 230VAC 4,8-35 lNO4976GOl REAR INTERFACE, CONTROL MODULE 4,8-35 lNO4976GOZ REAR INTERFACE, RS-232, CONTROL MODULE 1, 8-45 lNO497SGOl PCB, KEYBOARD/DISPLAY, CONTROL MODULE, ENGLISH 1, 8.45 lNO497SG03 PCB, KEYBOARD/DISPLAY, CONTROL MODULE, ITALIAN 1, 8-45 lNO497SG02 PCB, KEYBOARD/DISPLAY, CONTROL MODULE, FRENCH

Table 9-6. Replacement Parts for Flue Gas Temperature Probe

INDEX AND FIGURE NO. PART NO. DESCRIPTION I

1 8-46 1 8950075 1 THERMOCOUPLE,FLUEGAS I

SECTION X. RETURNING EQUIPMENT TO THE FACTORY

10-l. If factory repair of defective equipment is required, proceed as follows:

a. Secure a return authorization from a Rosemount Analytical Inc. Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount Analytical, Inc. instructions or it will not be accepted.

I” no event will Rosemount be responsible for equipment returned without proper authorization and identification.

b. Carefully pack defective unit in a sturdy box with sufficient shock absorbing material to ensure that no additional damage will occur during shipping.

E. In a cover letter, describe completely:

1. The symptoms from which it was determined that the equipment is faulty.

2. The environment in which the equipment has bee” operating (housing, weather, vibration, dust, etc.).

3. Site from which equipment was removed.

4. Whether warranty or nonwarranty service is expected.

5. Complete shipping instructions for return of equipment.

d. Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in Rosemount Return Authorization, prepaid, to:

A”llXiCan Rosemount Analytical Inc RMR Department 1201 N. Main Street Orrville, Ohio 44661

EUIODe”” Rosemount Analytical Inc. Equipment Return Repair Dept 151 Shannon Industrial Estate co. Glare Ireland

If warranty service is expected, the defective unit will be carefully inspected and tested at the factory. If failure was due to conditions listed in the standard Rosemount warranty, the defective unit will be returned to the customer in accordance with shipping instructions furnished in the cover letter.

For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions.

This index is an alphabetized listing of parts, terms, and procedures having to do with the Model 5100 CO Analyzer. Every item listed in the index refers to a location in the manual by page number or numbers.

A Absorption Coefficient, 3-31 Absorption Factor, 3-40 ACK Alarm, 3-13,3-30,7-l, 7-2 Address Bus, 6-3,6-12 Address Decoder Section, 6-3 Air Purge Blower Air Purge Filter, 8-39 Alarm 1,3-12 Alarm 1 Deadband, 3-29,3-35 Alarm 1 Key, 3-28 Alarm 1 Setpoint, 3-28,3-35 Alarm 1 Triac, 3-30 Alarm 2,3-12 Alarm 2 Deadband, 3-36 Alarm 2 Key, 3-30 Alarm 2 Setpoint, 3-30,3-35 Alarm 2 Triac, 3-30 Alarm3,7-1 Alarm Closure Points, 6-17 Alarm Setpoints, 3-11,3-22 Alarm Terminals, 2-9 ALIGN/RUN Switch, 3-8,4-l Alignment Flange, 2-3 Ambient Temperature Coefficients, 3-32 Analog Multiplexer, 6-6 Analog Output Format, 4-4 Analog Output Signal, 2-9,3-IO, 3-11,3-14,

3-21,7-2 Analog Section, 6-6 Analog to Digital Converter (A/D), 3-6,6-3,

7-2,7-10 Analyzer Function, l-2,3-14 Annunciating System, 3-9 Asynchronous Communication

Interface Adapter, 6-6,6-13 Audible Alarm, 3-13,3-30,7-l, 7-2 Automatic Calibration Frequency, 4-S Automatic Flue Gas

Temperature Compensation, 4-3 Automatically Initiated Calibration, 3-17,3-41,3-42 Average Intensities, 3-40

B Bandpass Filter, 3-1 Bandpass Filter Transmission, 3-1 Binary Count Circuit, 6-3,6-12

INDEX

B Binary Number System, 3-48 Blower, Air Purge Burner Flame Stoichiometry, l-l Buzzer Timer, 6-3

C Cal Qcle, 3-11 Cal Intensity Too Low Fault, 7-5 Cal Intensity Too High Fault, 7-$7-13 Cal Source Temp Amplifier, 6-6 Cal Zero Offsets Too High Fault, 7-5,7-13 Calcium Fluoride Window, 3-2,3-6,7-12,8-37 Calibration Cell In Beam Fault, 7-4,7-12 Calibration Cell Solenoid, 6-9 Calibration Cycle Frequency, 3-22 Calibration Cycle Zero Factor, 3-37,3-42 Calibration Gas Cell, 3-41,7-12,8-20 Calibration Gas Cell Assembly, 8-20 Calibration Source, 3-6,3-33,3-41,7-13 Calibration Source Heater, 3-41 Calibration Source Solenoid, 6-9,7-13 Calibration Source Triac, 7-13 Cal/Off Key, 3-17 Carbon Monoxide Cell, 8-13 Cell Energy Level, 3-4 Chopper Assembly, 8-23 Chopper Frequency, 3-3 Chopper Motor, 7-3&g-22,8-23 Chopper Motor Frequency, 6-6 Clamp Circuit, 6-3,6-12 CO Cell Intensity, 3-33,3-41,7-11 CO Concentration Value, 3-33 CO Reference Cell, 3-4 Cold Calibration Source, 7-13 Cold Junction Compensation, 3-6 Cold Junction Temperature, 3-33 Cold Junction Temperature Fault, 7-3,7-11 Collector Emitter, 6-9 Comm O.K., But Not Updating Fault, 7-6.7-13 Communication Failures, 7-2,7-4,7-H Communication Link, 7-8 Control Module, l-l, 3-6,3-g Control Module Failures, 7-9 Control Module Output Board, g-29,8-33 Control Module Power Supply Board, 8-33 Compressed Air Supply, 5-l Comparator, 6-1 Control System, 3-9 CPU Board, 3-6 CPU Section, 6-3,6-12 Crystal Oscillator Circuit, 6-3

IB-lE-SlOA I-1

D Damping Circuit, 3-4 Dark Level Test, S-15 Dark Level Value, 3.43,7-13 Data Acquisition System, 3-9 Data Multiplexer, 3-6 Deadbands, 3-11 Decoder Logic Circuit, 6-12 Decoder Section, 6-12 Detector, S-12 Detector System, 1-2 Detector Tube, 7-11 Diagnose Key, 3.27,7-2 Diagnostic Code Numbers, 3-27,7-l, 7-2 Diagnostic Parameters, 7-l Diagnostic Status, 7-I 1 Diagnostics Program, 3-12 Diagnostics System, 3-28 Digital Signal Processing, 1-2 Direct Voltage Output, S-7 Disabled, 3-12 Dual Gas Cell, 7.35,s.13 Dual Gas Cell Assembly, 3-3, 6-9 Dual Gas Solenoid, 6-9

E EEPROM, 3.6, 3.22,3-39, 6.3,6-12 EEPROM Write Error, 7.4,7-12 Electrostatic Precipitator, 2-1 Enable/Off Key, 3-30 Ext Meter Terminal, 4-1, 8-32

F Factory Code, 3-14, 3-39 Fault, 3-12,7-l Fault Flag, 3-28,7-l Fault Overrides, 7-2 Filter Bandpass, 3-3 Flue Gas Duct, 1-2 Flue Gas Opacity, 3-8 Flue Gas Temperature Fault, 7-3,7-l 1 FPS Units, 3.11,4-2 Full Scale Range, 3-19 Function Code, 3-13 Fuses, 9.1,9-2,9-3

G Gas Cell, 3-6 Gas Cell Solenoid, 8-17 Gas Filter Correlation, 1-2,3-l, 3-31 Gas Temp Amplifier, 6-6 Gas Temp Key, 3-16 Gas Temperature Compensation

Coefficients, 3-32, 8-14 Germanium Lens, 3.2,3-6

II Heat Sink, 8-4 Held Output, 3.10 Held Output Flag, 7-1 Held Output Mode, 3.22, 3-38 Heteroatomic Molecules, 3-l Hexadecimal Number System, 3.47 HoldFlag, 2-11,3-38,7-l Hold/Off Key, 3.21

I I/O Section, 6.3,6-13 Infrared Absorption Region, 3-1 Infrared Absorption Spectroscopy, 1-2,3-l, 3.31 Infrared Detector Output, 7-2 Infrared Energy, l-2, 3-2 Infrared Receiver Module, l-l, 2.1,3-2,3-6,7-2 Infrared Receiver Module Controls, 3-8 Infrared Source Module, l-l, 2.1,3-2, 3-4,4-l, 8-32 Infrared Source Module Controls, 3-9 Initial Zero Factor, 3.37 Input Filter, 3.33 Intensity Adjustment Potentiometer, 3-8, 4.1, 8-32 Intensity Too High Fault, 7-4,7-l 1 Intensity Too Low Fault, 7.4,7-12 Interconnect Cable, 2-7, 5-2 Interface Board, 3-6 Internal Calibration Gas Cell, 3-42 Internal Calibration Source, 3.36, 3-42 Isolated Range Outputs, 6-13

J Jet Pump, l-2, 2.11, 5-l J-Box, 8-7

K Keyboard, 3-11, 3-13

L Linearizer Circuit, 3-4 Lower Display, 3-11

M Main Source Temperature Control, 6-l MKS Units, 3-l 1,4-2 Man Gas T, 3-11 Manual Flue Gas Temperature Compensation, 4-3 Manual Gas Temperature, 7-l I Manually Initiated Calibration, 3-17, 3-42 Memory Section, 6.3,6-12 Molecular Absorption Characteristics, 3-31 Multiple Faults, 7-10

N Narrow Bandpass Optical Filtration, l-2,3-6,3-31 Negative Duct Pressures, l-2,2-11 Next Key, 3-20 Nitrogen Cell, 8-13 Nitrogen Cell Intensity, 3.33, 7.11 Nitrogen Cell Intensity Values, 3-43 Non-Maskable Interrupt (NMI), 6.1,6- 12

0 Operating Registers, 3-23 Operator Systems, 3-9 Optic System, 1-2 Optical Alignment, 8-32 Optical Bench, 3-6 Optical Path Length, 3.19,7-12 Output Filter, 3-l&3-33 Output Linearizer Coefficient, 3-32, 8-14 Output Truncation Format, 4-5

P Particulate Removal Device, 2-1 Periodic Wave Signal, 3-3 Peek, 3.47,7-37 Peripheral Interface Adapter (PIA), 3.6,6-3,6-13 Photo Chopper, 3-6 Photo Sensitive Transistor, 6-16 Photo Sensor, 3-6 Planoconvex Germanium Lens, 3-6 Poke, 3.47 Positive Duct Pressure Applications, 8-l Primary Function, 3.14,3-26 Printed Circuit Boards, 4-l Program Key, 3.26 Purge Air, 1-2,2-3,2-11,3-6,5-l Pyroelectric Detector, 3.1,3-3,3-6, 3.31

R Radiating Surface, 4-l Radiometer, 8-13 Radiometer Assembly, 3-6,3-31 Radiometer Temperature, 3-33, 7-2 Radiometer Temperature Fault, 7-3,7-l 1 Rear Interface Board, 8-35 Receiver Alignment, 8-32 Receiver CPU Board, 8-26 Receiver In Align Mode Fault, 7.5,7-13 Receiver Module Failures, 7-8 Recording Systems, 3-9 Reference Voltage, 3-36 Reference Voltage Adjustment, 8-31 Resp Time Key, 3.15

R Restore n Key, 3-25 Rotary Solenoids. 3-6 RS-422 Interface, 3-6 RS-232 Interface, 1-2, l-3,2-12,2-13,3-6, 3-7,6-13,

g-29,9-2,9-4

S Sample and Hold Amplifier, 3-4 Save n Key, 3.22 Schmitt Trigger Circuit, 6.3,6-12 Secondary Function, 3-14, 3-15 Set Zero, 3-11,3-18 Signal Processing Electronics, 1-2 Significant Digit, 3-49 Sink Current, 2-11 Software Timer, 6-3 Solenoid Drivers, 3-6 Solenoid Triacs, 6-9 Source Purge Air Assembly, 5-2 Source Heating Coil, 7.11 Source Intermediate Subassembly, 7-l 1, 8-2 Source Module Failures, 7-8 Source Temp Amplifier, 6-6 Source Temperature, 3-33 Source Temperature Control, 6-1,7-l 1 Source Temperature Fault, 7-3,7-l 1 Span Corrections, 3.39 Span Factor, 3-36 Speed Sensor Test, 8-16 Store Entry Key, 3.14,3-19,3-32, 3.39 System Data Bus, 6-1, 6-9 System Control Bus, 6.1,6-12 System Operating Span Factor, 3.42 System Operating Zero Factor, 3-37,3-42

T Temperature Control Circuit Board Stack, 8-2 Temperature Probe, l-l, 2.1,2-6 Temperature Setpoint Potentiometer, 3-9 Test Value, 3-11 Time Constant, 3.22,4-5 Thermal Stack Losses, l-l Thermocouple, 2-6, 2-9 Thermocouple Wire, 5-2 Triac Controller, 3-4 TTLInput, 2.11,3-38

U Upper Display, 3-10 User Key, 3.26 User Locked, 3-14,3-38

V Valid Memory Address (VMA), 6-l

w Watch Dog Section, 6-3.6-12 Weld Neck Flange, 2-3 Wet Flue Gas Desulfuriration System, 2-1 Wet Scrubbing Device, 2-1

z Zero Calibration Cycle, 3-l&3-39,4-6 Zero Correction, 3-39 Zero Factor, 3-18, 3-39

2540 267211 I-98

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