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Emerson Rosemount Analytical 400A Instruction Manual

Hydrocarbon analyzer
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Rosemount Analytical
M
400A
ODEL
H
A
YDROCARBON
NALYZER
I
M
NSTRUCTION
ANUAL
748262-K
NOTE
T
M
400A, C
N
194106
HIS MANUAL IS APPLICABLE TO
ODEL
ATALOG
UMBER
S
N
2000001
WITH
ERIAL
UMBERS BEGINNING WITH

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Summary of Contents for Emerson Rosemount Analytical 400A

  • Page 1 Rosemount Analytical 400A ODEL YDROCARBON NALYZER NSTRUCTION ANUAL 748262-K NOTE 400A, C 194106 HIS MANUAL IS APPLICABLE TO ODEL ATALOG UMBER 2000001 WITH ERIAL UMBERS BEGINNING WITH...
  • Page 2 OTICE The information contained in this document is subject to change without notice. ® Teflon is a registered trademark of E.I. duPont de Nemours and Co., Inc. ® SNOOP is a registered trademark of NUPRO Co. Instruction Manual 748262-K July 1997 Printed in USA Rosemount Analytical Inc.
  • Page 3 ONTENTS REFACE SAFETY SUMMARY ..................P-1 SPECIFICATIONS....................P-3 CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE ..P-5 RETURNING PARTS TO THE FACTORY ............P-5 TRAINING ......................P-5 DOCUMENTATION ....................P-5 1. I ECTION NTRODUCTION DESCRIPTION ..................1-1 ANALYZER MOUNTING OPTIONS ............1-1 FUEL GAS OPTIONS................1-2 OUTPUT OPTIONS..................1-3 1.4.1 Isolated Remote Range Change and Identification ....1-4 1.4.2 Range Trim Option..............1-4...
  • Page 4 ONTENTS 2. ( ECTION CONTINUED ELECTRICAL CONNECTIONS ............... 2-6 2.8.1 Line Power Connections ............2-6 2.8.2 Voltage Output Selection and Cable Connections for Recorder............... 2-7 2.8.3 Voltage to Current Output Board (optional)........ 2-7 2.8.4 Auxiliary Contacts............... 2-7 2.8.5 Remote Range Control and Indication ........2-7 2.8.6 Sample Pump Accessory ............
  • Page 5 ONTENTS 5. ( ECTION CONTINUED IGNITION CIRCUIT ..................5-7 SYSTEM POWER SUPPLIES..............5-7 FLAME-OUT BOARD ................5-8 6. S ECTION ERVICE AND ROUBLESHOOTING SYSTEM CHECKOUT................6-1 SERVICING FLOW SYSTEM AND BURNER ..........6-2 6.2.1 Burner Disassembly and Cleaning..........6-3 6.2.2 Thermistor...................6-4 6.2.3 Fuel and Air Restrictors ..............6-4 6.2.4 Sample Capillary.................6-4 TROUBLESHOOTING ................6-4...
  • Page 6 ONTENTS IGURES Range Input-Output Board............... 2-8 Range Control and Output Connections ..........2-10 Power Switch Location................3-2 Typical Curves of Downscale Response vs. Time for Various Hydrocarbons ................3-5 Example 1 Display ................... 3-7 Example 2 Display ................... 3-8 Example 3 Display ................... 3-8 Range Trim Option Schematic..............
  • Page 7 ONTENTS RAWINGS LOCATED IN REAR OF MANUAL 620424 Schematic Diagram, Preamplier 620429 Schematic Diagram, Main Electronics 620434 Schematic Diagram, Isolated V/I 622883 Flow Diagram, Model 400A 623190 Burner Parts List 624003 Schematic Diagram, Temperature Control Board 654328 Installation Drawing, Model 400A 654905 Schematic Diagram, Relay Board 654910...
  • Page 8 ONTENTS OTES Model 400A Hydrocarbon Analyzer July 1997 Rosemount Analytical 748262-K...

  • Page 9: Safety Summary

    REFACE AFETY UMMARY To avoid explosion, loss of life, personal injury and damage to this equipment and on-site property, all personnel authorized to install, operate and service the Model 400A Hydrocarbon Analyzer should be thoroughly familiar with and strictly follow the instructions in this manual.
  • Page 10 REFACE WARNING: POSSIBLE EXPLOSION HAZARD Do not apply power to analyzer or ignite burner until all leak checks have been performed and until the environment of the analyzer has been determined to be non-hazardous. See Section 2.7 for leak check procedure. This instrument uses a fuel containment hydrogen.

  • Page 11: Specifications

    REFACE PECIFICATIONS 115 VAC ±10%, 50/60 ±3 Hz, 250 W OWER EQUIREMENTS 32°F to 110°F (0°C to 43°C) PERATING EMPERATURE Controlled at 122°F (50°C) EMPERATURE 95% relative humidity, but not in excess of 34°C wet MBIENT UMIDITY bulb temperature. 8.75 in (22.2 cm) H 18.75 in.
  • Page 12 REFACE PECIFICATIONS CONTINUED Eight ranges: 1, 2.5, 10, 25, 100, 250, 1000 and REMOTE. ANGE In addition SPAN control provides continuously variable adjustment within a dynamic range of 4:1 1) 0 to 5 VDC, 0 to 1 VDC, 0 to 0.1 VDC fully buffered - standard (for 0 to 100.0%).

  • Page 13: Training

    REFACE USTOMER ERVICE ECHNICAL SSISTANCE AND IELD ERVICE For order administration, replacement Parts, application assistance, on-site or factory repair, service or maintenance contract information, contact: Rosemount Analytical Inc. Process Analytical Division Customer Service Center 1-800-433-6076 ETURNING ARTS TO THE ACTORY Before returning parts, contact the Customer Service Center and request a Returned Materials Authorization (RMA) number.
  • Page 14 REFACE OTES Model 400A Hydrocarbon Analyzer July 1997 Rosemount Analytical 748262-K...

  • Page 15: Description

    NTRODUCTION 1.1 DESCRIPTION The Model 400A Hydrocarbon Analyzer automatically and continuously measures the concentration of hydrocarbons in a gas stream. Typical applications include monitoring atmospheric air for low-level hydrocarbon contaminants and determining the hydrocarbon content of exhaust emissions from internal combustion engines. The analyzer utilizes the flame ionization method of detection.

  • Page 16: Fuel Gas Options

    NTRODUCTION The standard analyzer is housed in a case designed for bench-top use, or if desired, the analyzer may be mounted in a cabinet or rack using RETMA spaced mounting holes. Outline dimensions are shown on DWG 654328. 1.3 FUEL GAS OPTIONS For burner fuel gas, the standard analyzer requires 40% hydrogen/60% nitrogen or helium.

  • Page 17: Output Options

    NTRODUCTION It is worth noting that with a 40/60 premixed fuel, the above flows amount to 40 cc (8%) hydrogen, 67 cc (13%) inert plus sample and 400 cc (79%) air, which compare closely to the 30 cc (8%) hydrogen, 45 cc (12%) inert/sample and 300 cc (80%) air given earlier for straight hydrogen fuel.

  • Page 18: Sample Pump Option

    NTRODUCTION 1.4.1 I SOLATED EMOTE ANGE HANGE AND DENTIFICATION This option provides a 24 VDC operation of remote range and identification as well as providing terminals for flame out indication. 1.4.2 R ANGE PTION This option provides individual potentiometers for each range to allow adjustment of individual differences in bottled gas.

  • Page 19: Unpacking

    NSTALLATION 2.1 UNPACKING Carefully examine the shipping carton and contents for signs of damage. Immediately notify the shipping carrier if the carton or its contents are damaged. Retain the carton and packing materials until the instrument is operational. 2.2 LOCATION Install analyzer in a clean area, not subject to excessive vibration or extreme temperature variations.

  • Page 20: Fuel And Air Requirements

    NSTALLATION This instrument was shipped from the factory configured to operate on 115 VAC, 50/60 Hz electric power. Verify that the power source conforms to the requirements of the individual instrument, as noted on the name-rating plate. Note: 230 VAC operation requires an accessory transformer mounted external to the instrument.

  • Page 21: Sample Handling

    NSTALLATION 2.4.2 A Burner air should also be relatively free of hydrocarbons in order to assure a low background signal. Several grades of air are supplied by various gas vendors for this use. A maximum total hydrocarbon content of less than 1 ppm (THC < used as a zero standard).

  • Page 22: Gas Connection

    NSTALLATION WARNING: POSSIBLE EXPLOSION HAZARD In the event that flammable sample is to be introduced into this analyzer, it must be equipped with accessory kit PN 624080, which restricts sample flow and provides automatic sample shutoff in the event of burner flameout. DO NOT OPERATE WITHOUT SAMPLE FLOW RESTRICTOR IN PLACE.
  • Page 23 NSTALLATION 2. If a vent line is to be connected to exhaust outlet, use 1/2-inch ID tube slanted downward at least 10 degrees from horizontal. Note: Since water vapor is formed during oxidation of hydrogen, burner exhaust gas always contains moisture, even if air and fuel entering the burner are completely dry.

  • Page 24: Electrical Connections

    NSTALLATION 2.7 LEAK CHECK WARNING: POSSIBLE EXPLOSION HAZARD Be particularly careful in checking for leaks in the fuel lines. Fuel gas leakage can cause an explosion. Check all gas connections to ensure that they are leak free. Use of SNOOP (P/N 837801) or other suitable leak-test liquid is recommended.
  • Page 25 NSTALLATION 2.8.2 V OLTAGE UTPUT ELECTION AND ABLE ONNECTIONS FOR ECORDER The standard analyzer provides voltage output only. As shipped from the factory, the analyzer is set up for use with a 100 mV recorder (program header connecting pins E9 and E10).

  • Page 26: Range Control

    NSTALLATION ANGE ONTROL SOLATED Terminals 1 through 7 on the upper terminal block at the rear of the instrument are used for this function. Select RMT on the front panel RANGE switch. Connect the respective line, 1 through 7, to pin 3 (labeled GND) on the lower barrier strip. The front panel will indicate the range selected.
  • Page 27 NSTALLATION SOLATED EMOTE ANGE ONTROL AND DENTIFICATION The Remote Control Assembly is located on the rear panel of the instrument and is shown in Figure 2-2. Connections should be made to the terminals marked Range Control where a single line interference is desired. By removing steering diodes on printed circuit board 654910, individual Range Control and Range I/O connections may be made.
  • Page 28 NSTALLATION OUTPUT FLAME OUT V mA 24VDC MAX TS12 CONTROL LINES 24 VDC, 150 Mw REMOTE ALL CONTACTS 24 VDC MAX, 1 A MAX CURRENT OUTPUT 600 OHMS MAX TS10 RANGE ID 24 VDC MAX TS11 RANGE CONTROL 24 VDC SINGLE LINE CONTROL/SENSE USE "RANGE CONTROL"...

  • Page 29: Initial Startup And Calibration

    TARTUP AND ALIBRATION 3.1 INITIAL STARTUP AND CALIBRATION Section 3.1.1 discusses calibration methods and the associated standard gases. Section 3.2 explains the typical calibration procedure. After installing analyzer per Section Two, proceed as follows: 1. Set the RANGE multiplier switch (located inside the small door on the analyzer front panel) at 1000.
  • Page 30 TARTUP AND ALIBRATION Fuel Gas Internal Pressure 100% H2 Fuel Mixed Fuel Regulator psig/kPa psig//kPa 5/35 5/35 Fuel 25/175 30/207 Sample 5/35 3-1. I ABLE NTERNAL RESSURE EGULATORS ETTINGS The PURGE/IGNITE switch has two positions, IGNITE and PURGE. 5. With PURGE/IGNITE switch in PURGE position, wait about one minute for fuel gas to purge flow system.
  • Page 31 TARTUP AND ALIBRATION Note: If ignition indication [FLAME ON] is observed without obtaining proper sensitivity, refer to Table 6-1, Item 6. Note: When lighting the burner after extended shutdown, the instrument will require time to allow fuel to reach the burner. Therefore, extended operation of the switch may be required.
  • Page 32 TARTUP AND ALIBRATION 9. With flame burning, allow system to stabilize for at least two hours, and preferably for a day. After initial startup, or after startup following a prolonged shutdown, the analyzer may display baseline drift for a considerable period of time, particularly on the more-sensitive ranges.

  • Page 33: Calibration Procedure

    TARTUP AND ALIBRATION Sample CH (Methane) Sample C (Propane) Analyzer Response Sample C (Hexane) Time 3-2. T IGURE YPICAL URVES OF OWNSCALE ESPONSE VS IME FOR ARIOUS YDROCARBONS PSCALE ALIBRATION OINT In all applications, the upscale calibration point is established by adjustment of the SPAN control, while a standard gas of accurately known hydrocarbon content is flowing into the SAMPLE inlet port.

  • Page 34: Range Switch

    TARTUP AND ALIBRATION a. Supply zero gas to SAMPLE inlet. Adjust external flow controller or throttle valve so that flow discharge from BY-PASS outlet is between 0.5 and 3.0 liters/minute (preferably between 2.0 and 3.0 liters/minute). Set internal SAMPLE pressure regulator at 5 psig (34 kPa) or other desired value. (Recommended operating range is 4 to 5 psig [28.6 to 34 kPa] for analyzer using 100% hydrogen fuel, and 1.5 to 5 psig [10 to 34 kPa] for analyzer using mixed fuel.)
  • Page 35 TARTUP AND ALIBRATION RANGE SWITCH APPROXIMATE OPERATING RANGE SPAN SETTINGS CONTROL AT 1000 0 to 1 ppm CH4 0 to 4 ppm CH4 0 to 2.5 ppm CH4 0 to 10 ppm CH4 0 to 10 ppm CH4 0 to 40 ppm CH4 0 to 25 ppm CH4 0 to 100 ppm CH4 0 to 100 ppm CH4...

  • Page 36: Range Trim Option

    TARTUP AND ALIBRATION XAMPLE After the calibration in Example 1, Range automatically 75.0 calibrated for 80 ppm CH as 100% fullscale. (Note that Range 10 is 4 PERCENT OF RANGE RANGE times less sensitive than Range 2.5). Therefore, when the operator switches RANGE MULTIPLIER from Range 2.5 to Range 10, the 25 100...
  • Page 37 TARTUP AND ALIBRATION FIXED R10 5K TRIM SPAN -5V REF ZERO AGND DGND 3-6. R IGURE ANGE PTION CHEMATIC 748262-K Rosemount Analytical July 1997 Model 400A Hydrocarbon Analyzer...
  • Page 38 TARTUP AND ALIBRATION OTES 3-10 Model 400A Hydrocarbon Analyzer July 1997 Rosemount Analytical 748262-K...

  • Page 39: Routine Operation

    PERATION 4.1 ROUTINE OPERATION After calibrating instrument per Paragraph 3.2, proceed as follows: Supply sample gas to SAMPLE inlet. Adjust external flow controller or throttle valve so that flow discharged from BY-PASS outlet is between 0.5 and 3.0 liters/minute (preferably between 2.0 and 3.0 liters/minute). Note reading on BY-PASS pressure gauge.

  • Page 40: Obtaining Maximum Sensitivity

    PERATION 4.4 OBTAINING MAXIMUM SENSITIVITY If maximum sensitivity is desired, it is necessary to use an optimum combination of settings on the SAMPLE, FUEL, and AIR pressure regulators. Settings must be determined experimentally; however, the curves of Figures 4-1, 4-2 and 4-3 on the following pages may be used as a guide.
  • Page 41 PERATION AIR: 30 psig AIR: 30 psig AIR: 30 psig RESPONSE (100 ppm CH fullcale) SAMPLE: 100 ppm CH in N @ 5 psig 34.4 68.8 103.2 172.6 206.4 137.6 SAMPLE PRESSURE psig 4-2. T IGURE YPICAL URVES OF NALYZER ESPONSE VS RESSURE ETTING ON...
  • Page 42 PERATION OTES Model 400A Hydrocarbon Analyzer July 1997 Rosemount Analytical 748262-K...

  • Page 43: Principles Of Operation

    HEORY 5.1 PRINCIPLES OF OPERATION The Model 400A Hydrocarbon Analyzer utilizes the flame ionization method of detection. The sensor is a burner in which a regulated flow of sample gas passes through a flame sustained by regulated flows of air and a fuel gas (hydrogen or a hydrogen/diluent mixture).
  • Page 44 HEORY Streams of sample, fuel and air delivered by the analyzer flow system (Section 5.3) are routed through internal passages in the manifold and into the interior of the burner. Here the sample and fuel pass through the burner jet and into the flame; the air stream flows around the periphery of the flame.

  • Page 45: Approximate Effective Carbon Numbers

    HEORY EFFECTIVE CARBON TYPE OF ATOM OCCURRENCE NUMBER Carbon In Aliphatic Compound +1.00 Carbon In Aromatic Compound +1.00 Carbon In Olefinic Compound +0.95 Carbon In Acetylenic Compound +1.30 Carbon In Carbonyl Radical 0.00 Carbon In Nitrile +0.30 Carbon In Ether -1.00 Carbon In Primary Alcohol...

  • Page 46: Analyzer Flow System

    HEORY 5.3 ANALYZER FLOW SYSTEM The internal flow system of the analyzer is shown in drawing 622883. Its basic function is to deliver regulated flows of sample, fuel, and air to the burner. In addition, the system routes the burner exhaust gas and sample bypass flow out of the analyzer through the corresponding outlet ports.

  • Page 47: Range Switch Settings

    HEORY A buffer signal offering unity gain and noise filtration provide a low output impedance to drive the signal cable and post amplifier circuits on the main circuit board. Selection of the low or high range feedback resistors is made by relay K1 on the preamplifier board.

  • Page 48: Span

    HEORY presentation to read directly in percent of fullscale and still have 100% overrange capability remaining. 5.5.3 S To compensate for various calibration gases, provision is made to vary the gain with a variable span control. The variable span, accessed on the front panel through a calibrated potentiometer, allows gain variation of 400%.

  • Page 49: Ignition Circuit

    HEORY The temperature control board is a multi-purpose board with a control resistor that is factory-selected for the model analyzer in which it is used. Schematic 624003 shows the correct jumper position for the Model 400A Note: 230 VAC operation requires an accessory transformer mounted external to the instrument.

  • Page 50: Flame-Out Board

    HEORY 5.9 FLAME-OUT BOARD Refer to schematic 657546 in the rear of this manual. Loss of the flame shuts down the fuel solenoid. If there is a flammable component in the sample, a fail safe solenoid accessory is available for wiring in parallel with the fuel solenoid. Model 400A Hydrocarbon Analyzer July 1997 Rosemount Analytical...

  • Page 51: System Checkout

    ERVICE AND ROUBLESHOOTING WARNING: ELECTRICAL SHOCK HAZARD Do not operate without doors and covers secure. Servicing requires access to live parts which can cause death or serious injury. Refer servicing to qualified personnel. For safety and proper performance this instrument must be connected to a properly grounded three-wire source of power.

  • Page 52: Servicing Flow System And Burner

    ERVICE AND ROUBLESHOOTING LAME GNITION Start up analyzer per Section Three, and attempt to ignite flame. If flame will not ignite refer to Table 6-1, Item 2. OISE HECK With flame burning, observe indicator or recorder. If noise is greater than 2% of fullscale, refer to Table 6-1, Item 3.
  • Page 53 ERVICE AND ROUBLESHOOTING 6.2.1 B URNER ISASSEMBLY AND LEANING Disassemble the burner only if contaminants must be removed. Combustion products or other contaminants which accumulate inside the burner may form electrical leakage paths between the collector and the burner contact, resulting in noisy readings. If the instrument is to be operated at the highest sensitivity, traces of such contaminants can cause erroneous readings.

  • Page 54: Troubleshooting

    ERVICE AND ROUBLESHOOTING Using care not to touch internal parts, reassemble burners as explained in the following steps. 1. Holding burner tip assembly with clean tissue, screw finger-tight into manifold. 2. Push combustion chamber down onto manifold, taking care not to hit burner tip. Tighten clamp on combustion chamber.
  • Page 55 ERVICE AND ROUBLESHOOTING SYMPTOM PROBABLE CAUSE POSSIBLE REMEDY Indicator shows Electrical leakage in burner upscale reading Clean burner per Section 6.2.1 assembly. when flame is out. Purge FUEL pressure regulator Fuel gas emerging from burner jet by allowing gas to flow for diluted with other gases because several minutes, while turning fuel system is insufficiently purged.
  • Page 56 ERVICE AND ROUBLESHOOTING SYMPTOM PROBABLE CAUSE POSSIBLE REMEDY Check filters; replace if Fuel and/or air filter clogged. necessary. Verify that fuel and air restrictors and sample capillary are open. An abnormally low background signal, together with sensitivity loss, indicates Plugged restrictor or capillary plugged restrictor.

  • Page 57: Circuit Board Replacement Policy

    EPLACEMENT ARTS WARNING: PARTS INTEGRITY Tampering or unauthorized substitution of components may adversely affect safety of this product. Use only factory documented components for repair 7.1 CIRCUIT BOARD REPLACEMENT POLICY In most situations involving a malfunction of a circuit board, it is more practical to replace the board than to attempt isolation and replacement of the individual component.
  • Page 58 EPLACEMENT ARTS 621017 Header 655178 Door, Clear Plastic 655203 Valve, Solenoid (Sample Shutoff) (Option) 017154 Filter, Sample/Air 898767 Filter, Mixed Fuel See drawing 623190 for listing of capillaries and restrictors, and for Burner Parts List. Model 400A Hydrocarbon Analyzer July 1997 Rosemount Analytical 7482626-K...

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