Related Manuals for Ametek Dycor CG1100 Series
Summary of Contents for Ametek Dycor CG1100 Series
- Page 1 Dycor CG1100 Oxygen Analyzer User Manual Process Instruments 150 Freeport Road Pittsburgh, PA 15238 PN 90484VE, Rev. J...
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Page 2: Offices
If the instrument or procedures are used for purposes over and above the capabilities specified herein, confirmation of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents. -
Page 3: Table Of Contents
Contents Offices ........................ii Safety Notes ......................vi Electrical Safety ..................... vi Grounding ......................vi Warning Labels ....................vii Environmental Information (WEEE) ............... vii Electromagnetic Compatibility (EMC) ............viii European Standards Information ..............ix CHAPTER 1 CG1100 Oxygen Analyzer Overview ......................1-1 Controller / Communications .............. - Page 4 CHAPTER 4 Controller / User Interface System Start-Up ....................4-1 Setting up System Parameters ..............4-1 PC Requirements for Configurator Software ......... 4-1 Configurator Software Installation ............4-2 Configuring Your Device .................. 4-3 General Tab ....................4-3 Device Communications Tab ..............4-5 Setup Tab .......................
- Page 5 APPENDIX A Communications Protocol Protocol Summary .....................A-1 Addresses ......................A-2 Defined Responses (slave to master) ..............A-3 Function Codes ....................A-4 Variables .......................A-6...
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Page 6: Safety Notes
Safety Notes wARnings, cAuTions, and noTEs contained in this manual emphasize criti- cal instructions as follows: An operating procedure which, if not strictly observed, may result in personal injury or environmental contamination. An operating procedure which, if not strictly observed, may result in damage to the equipment. -
Page 7: Warning Labels
Achtung - Heiße Oberfläche Environmental Information (WEEE) This AMETEK product contains materials that can be reclaimed and recycled. In some cases the product may contain materials known to be hazardous to the environment or human health. In order to prevent the release of harmful substances into the environment and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reached its “end of life”. -
Page 8: Electromagnetic Compatibility (Emc)
Electromagnetic Compatibility (EMC) Read and follow the recommendations in this section to avoid perfor- mance variations or damage to the internal circuits of this equipment when installed in harsh electrical environments. The various configurations of the CG1100 Oxygen Analyzer should not produce, or fall victim to, electromagnetic disturbances as specified in the European Union’s EMC Directive. -
Page 9: European Standards Information
European Standards Information AMETEK Process Instruments (ISO 9001 Registered 1995) Manufacturer’s Name: Process & Analytical Instruments Division Manufacturer’s Address: 150 Freeport Road Pittsburgh, PA, 15238 USA Phone: 412-828-9040 Fax: 412-826-0686 Dr. Jurgen Gassen EU Representative Address: AMETEK Precision Instruments Europe GmbH... - Page 10 Process photometric analyzers, process moisture analyzers, and sampling systems are warranted to perform the intended measurement, only in the event that the customer has supplied, and AMETEK has accepted, valid sample stream composition data, process conditions, and electrical area classification prior to order acknowledgment.
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Page 11: Chapter 1 Cg1100 Oxygen Analyzer
For enhanced interface and process monitoring, AMETEK offers optional System 2000 software with graphical user inter- face to record and process your data in a Windows 95/NT format. User- provided software can also be used with the CG1100 serial port. -
Page 12: Sensor Operations
Sensor Operations Disconnect AC power from the analyzer before performing any main- tenance or troubleshooting. The furnace and furnace insulation cover are hot during normal opera- tion (up to 500 °F, 260 °C inside the furnace insulation cover). Allow analyzer components to cool for at least an hour before working inside the analyzer. - Page 13 since the voltage of the cell is temperature-dependent, the cell is maintained at a constant temperature. some newer high-temperature insitu models use the heat from the process to heat the sensor; the process temperature is continu- ously measured and used in the software calculation. The oxygen content is then determined from the Nernst equation.
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Page 14: Ems Grounding, Shielding, And Noise Protection
Proper Sensor Operations Follow these general guidelines when using the CG1100 analyzer: • Do not use pipe dope on any joints of the sample tubing, or any other contaminant that gives off combustible vapor which can cause errone- ous measurements. •... -
Page 15: Transient And Rfi Interference
Transient and RFI Interference Follow general grounding and shielding requirements for all wiring as described in the wiring section of Chapter 2. NOTE Do not run control unit AC mains supply wiring in the same conduit with other AC mains supply wiring. By keeping this wiring separate, you prevent transient signals from reaching the control unit. -
Page 16: Technical Support
Technical Support AMETEK/Dycor is committed to providing you the best technical support in the industry. If you need service or application assistance, please call AMETEK at (412) 828-9040, or your local AMETEK/Dycor representative. If you need to return equipment, you will be asked to provide the follow- ing information before obtaining a Return Material Authorization (RMA) number. -
Page 17: Chapter 2 Specifications
24 VDc ± 5%, 2.7 A, less than 100 mv noise or ripple. An optional external 24V power supply is available with 100-250 Power VAc, 47-63 Hz input (AMETEK #25446JE). Requirements when using an external power supply, a power connector plug (AMETEK #19674JE) is required. - Page 18 Configurator software is used to configure and calibrate the analyzer. Requires a PC with Windows and an RS-232 serial port for single Software analyzer, or Rs-485 port for multiple units on a network. optically isolated Rs-232 (one DB-9F connector), and Rs-485 (two DB-9F connectors) Rs-232 selected if RTs signal is set.
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Page 19: Chapter 3 Installation
INSTALLATION This chapter includes the following: • Mechanical Installation Sample gas requirements Sample gas set-up Calibration gas set-up PPM measurement suggestions • Electrical Installation Wiring Alarm contact connections Output Wiring Status LEDs and Alarms Connection to Line Power There are no operator-serviceable components inside the CG1100. Never open the analyzer cover. - Page 20 Pressure (Torr) Figure 3-1. Minimum pressure drop vs. flow 3-2 | Dycor CG1100 Oxygen Analyzer...
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Page 21: Mechanical Installation
Mechanical Installation Sample Gas sample Flow Requirements/Connec- sample gas/calibration gas set-up tion PPM Measurement suggestions Sensor 0 °c to 40 °c (32 °F to 104 °F) Ambient Temperature Range Sample Flow Rate 50 to 200 sccm. Depends on user application. see note below. Max Sample Flow Rate 200 sccm;... -
Page 22: Analyzer Description
Analyzer Description RS-485 RS-485 RS-485 Network Address Switches Network Address Switches Network Address Switches Green Green Green Yellow Yellow Yellow RS-232 RS-232 RS-232 RS-485 RS-485 RS-485 RS-485 RS-485 RS-485 0-5V Analog/Digital I/O Analog/Digital I/O Analog/Digital I/O Optional Output Power Connector Power Connector Power Connector Plug... - Page 23 Sample Figure 3-3. Rear of CG1100 analyzer. sample gas in Used to allow flow of cal gases or sample gas. 3-way Valve The cal gas port is used to connect a calibration gas cal gas Port to the system. ...
- Page 24 Gas OUT Mass Flow Meter Gas IN Cell Figure 3-4A. Sample gas flow CG1100 (front view). Mass Flow Meter Mass Flow Meter GAS IN GAS IN GAS OUT GAS OUT Figure 3-4B. Sample gas flow CG1100 (side view). 3-6 | Dycor CG1100 Oxygen Analyzer...
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Page 25: Sample Gas Flow
Sample Gas Flow Sample Gas Requirements The sample gas should be clean and dry. note that hydrocarbons and combustibles in the sample will oxidize with available oxygen in the sample to provide lower-than-expected oxygen levels. Be aware of this, especially if measuring oxygen in the low PPM ranges. -
Page 26: Calibration Gas Requirements
Connect a PC to the RS-232/RS-485 port of the analyzer and run the configurator soft- ware. click on the software Setup tab to read the flow. If the sample gas pressure is less than or equal to atmospheric pressure, open the meter- ing valve to full OPEN position. -
Page 27: Calibration Gas Set-Up
Calibration Gas Set-Up 3-Way Valve Cal Gas Regulator Inlet Zero 1/8" tubing 1/8" 1/4" tubing Vacuum Compression 150 sccm Generator Fitting Outlet CG1100 Set for 3 psi. Span 2 scfh Mechanical Flow Meter Figure 3-6 Calibration Gas Set-Up set the 3-way valve on the back of the analyzer to OFF. connect the calibration, span and zero gases to the 3-way valve. -
Page 28: Ppm Measurement Suggestions
PPM Measurement Suggestions This section provides help on how to use the CG1100 in the low PPM ranges: Gas Sample Bypass A good practice in the measurement of PPM gas concentrations (during calibration or initial start-up) is to provide a bypass on the gas sample inlet to the analyzer. -
Page 29: Installation Of Electrical Components
Installation of Electrical Components • Electrical Installation • Wiring Verification • 4-20 mA Output Wiring • RS-232 and RS-485 Cable Connections • Alarm Contact Connections • 0-5 Volt Output Wiring • Pinout Reference • Status LEDs and Alarms • Connecting to the Power Line Electrical Installation connect the 4-to-20 mA analog output and alarm contacts from the ana- lyzer to your recording equipment. Refer to Figure 3-9. or, connect the 0-5 volt analog output and alarm. - Page 30 The 0-5 volt board is plugged into the analog board solder- side up. 0-5V Board Component side of this board faces the component side of the analog board. Figure 3-8. Analog board for CG1100 analyzer. 3-12 | Dycor CG1100 Oxygen Analyzer...
- Page 31 Loop-Powered The external voltage source must be no greater 4-to-20 mA output, Loop-Powered Connector than 30 volts DC. To determine the minimum Internal Jumper JP5 - Jumper Pins 1-2 and 3-4. external voltage supply required to power the current outputs, use the following formula: Analog/Digital I/O Connector VEXTmin = .02 amps (RLoad + Rwires) + 6 volts.
- Page 32 To enable RS-232 communications, DTR (Pin 4) must be active. If DTR is not available from the host, connect Pin 8 to Pin 4 at the CG1100 using cable (AMETEK#74508SE). NOTE 9-Pin PC Connector 25-Pin PC Connector CG1100 CG1100...
- Page 33 4-WIRE Converter Part # 73858SE TD(A) TD(B) ECHO OFF ON RD(A) RD(B) RS-485 RS-232 Power +12V CG1100 DB-9 Supply (Type DB9M) 2-WIRE Converter Part # 73858SE TD(A) RX-(A) TD(B) RX+(B) RS-485 RS-232 CG1100 DB-9 (Type DB9M) Figure 3-11. RS-485 to RS-232 conversion for host PC, 4-wire and 2-wire. Installation | 3-15...
- Page 34 To enable RS-232 communications, DTR (Pin 4) must be active. If DTR is not available from the host, connect Pin 8 to Pin 4 at the CG1100 using cable (AMETEK#74508SE). NOTE The RS-232 adapter cable is used to activate the RS-232 port on the front of the CG1100 analyzer.
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Page 35: Alarm Contact Connections
Alarm Contact Connections This section describes how to make the wiring connections for alarm devices that you want to set up on the CG1100. Information on how to set up alarms in software is described in Chapter 4. The I/O connector on the front of the CG1100 analyzer contains alarm pin- outs (see Figure 3-2): The Watchdog Timer alarm is associated with the following pins on the I/O connector:... -
Page 36: Output Wiring
Output Wiring The CG1100 has two output configurations: 4-20 mA output 0 to 5 volt output. if the front of your analyzer has a “0-5V output” label to the left of the Analog/ Digital I/O Connector (see Figure 3-2), then the unit is configured for a 0-5 volt output. -
Page 37: Status Leds And Alarms
Communication status; flashing during communication YELLOW Alarm Source / LED Flashes / Problem Action Cycle RAM or EEPROM Hardware Failure call AMETEK service Failure General System Hardware Failure call AMETEK service Failure Calibration Analyzer performance Perform gas calibration Required... -
Page 38: Connect The Cg1100 To The Line Power
When using an external power source, a connector is required for the power input on the front of the CG1100. The connector is a plug with a 30° lock ring and 4 pins at 210° (Switchcraft #09CL4M, AMETEK NOTE Part Number# 19675JE). -
Page 39: Chapter 4 Controller / User Interface
Plug the power connector from a 24 VDc power supply into the power entry module on the front of the analyzer. if you are using an AMETEK 24 VDc power supply (Pn:25469JE), plug the cord of the power supply into the appropriate Ac power outlet. -
Page 40: Configurator Software Installation
Configurator Software Installation 1. Insert the Setup Disk 1 into your floppy disk drive. 2. Click RUN . . . from the Windows Start Menu. 3. Type the drive letter, followed by a colon(:) and a backslash (\) and the word “setup.”... -
Page 41: Configuring Your Device
Configuring Your Device General Tab Defines device and communications settings . Figure 4-1. General tab configurator software. Device Name Provides a name for the device. Description Provides optional description information. Saves analyzer internal parameters to a file. The Save As dialog Save Configuration box will appear so that you can name the file. - Page 42 Figure 4-2. Serial port configuration under PC Communication setup button. PC communications Setup click the Setup button to set-up Pc communications. select the coM port on the computer used to connect to you Port device. select the baud rate at which data will be transferred. (Either Baud Rate 9600 or 19200) RS-232 Port...
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Page 43: Device Communications Tab
Device Communications Tab Figure 4-3. Device Communication tab for configurator Baud rate select the baud rate at which data will be transferred. RS-485 Identifies the analyzer’s address and the type of serial com- munication cable being used. Address Type the network address for the device being connected. 2-wire RS-485 click if device is using 2-wire serial cable. -
Page 44: Setup Tab
Setup Tab Defines system parameter settings. Figure 4-4. Setup tab for configurator software. Carrier gas specify the sample gas stream being analyzed in the list box. Pressure Enter the inlet pressure. Define calibration settings. Concentration Enter span gas in percent or PPM. initiate span gas. check reading on the Status tab until o reading stabilizes. -
Page 45: Alarm Tab
Alarm Tab Defines alarm settings. Figure 4-5a/b. Alarm tab on configurator software. Alarm output 1 Disabled Disable alarm. Oxygen Enable oxygen alarm. Flow Enable flow alarm. High limit Enter high limit value. Low limit Enter low limit value. Alarm output 2 Disabled Disable alarm. -
Page 46: Analog Tab
Analog Tab Defines analog output settings. Figure 4-6 a/b. Analog tab on configurator software. Analog output selectable for oxygen and flow Disabled Disable analog output. Oxygen Enable oxygen analog output. Flow Enable flow analog output. Full Scale Enter upper range output value. Zero Enter lower range output value. -
Page 47: Calibration Tab
Calibration Tab Defines type of calibration. Figure 4-7. Calibration tab. Dual gas calibration. Span & zero click to calibrate on both span and zero gas. Span only single gas calibration. click to calibrate span gas only. Zero only single gas calibration. click to calibrate zero gas only. Begins calibration for span gas. -
Page 48: Verification Tab
Verification Tab Verify calibration readings based on percent error. Figure 4-8. Verification tab. Use span gas click to verify the span gas. Use zero gas click to verify the zero gas. Click to begin verification. Verify Acceptable range Enter the acceptable error range value in percent. Indicates results of last verification using the last Last verification reference, verification result and percent error. - Page 49 Status Tab Indicates current reading and status of CG1100. Figure 4-9. Status tab on configurator software. Oxygen reading current oxygen reading in percent. Cell temperature current temperature in degrees c. Current sample flow in sccm. Flow Right below the analyzer status box (on-line) is a box Error box that displays error messages.
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Page 51: Chapter 5 Calibrating The Cg1100-Rtp
CALIBRATING THE CG1100-RTP All oxygen alarms are disabled during calibrations. NOTE Calibration The span gas is the high o concentration calibration gas. The zero gas is the low o concentration calibration gas. NOTE set up your analyzer for a calibration gas procedure. see chapter 3 - Installation. - Page 52 This page intentionally left blank. 5-2 | Dycor CG1100 Oxygen Analyzer...
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Page 53: Chapter 6 Diagnostic Checks And Troubleshooting
DIAGNOSTIC CHECkS AND TROUBLESHOOTING Diagnostics Checks We recommend that the temperature, pressure, oxygen reading and flow be recorded as a troubleshooting aid. This information will be helpful should you need to contact the factory for assistance. Be sure NOTE to always include your analyzer model and serial number when call- ing the factory for technical support. -
Page 54: Wiring Checks
Wiring Checks Wiring Problem Make sure all wiring connections are terminated to the proper locations and are seated properly. This includes ensuring that sets of wires are not reversed, and that the cable is not damaged. Analog Board Connections Connection Connector Label Wire Connection TB2 - Pin 1... -
Page 55: Hermocouple Checks
Thermocouple Checks Thermocouple Checks Open Thermocouple Disconnect power to the analyzer. Disconnect TB5 plug from the analog board and measure the resistance across the terminals. If an open is measured, replace the thermocouple. Shorted/Failed Thermocouple check that the thermocouple leads are not shorted to chas- sis ground. -
Page 56: Calibration Setup Checks
Calibration Setup Checks Calibration Setup Checks Calibration Gas Check Check that the correct calibration Are the calibration gas cylinders turned on? Are they empty? gas values have been entered into Does the calibration gas bottle pressure have at least 500 the control unit. -
Page 57: Furnace Checks
Furnace Checks Open Furnace Disconnect power to the analyzer. Disconnect plug TB6 and, with an ohm meter, measure the resistance across TB6, Pins 1 and 2 on the analog board. The resistance of the fur- Furnace Checks nace should be between 12 and 13 ohms at room tempera- ture. -
Page 58: General Troubleshooting
General Troubleshooting General Troubleshooting Leak Check Sniff the fittings with 100% oxygen using a piece of tygon Your system may pass calibrations or plastic tubing with a 1/8” stainless steel nozzle to apply yet still seem to be reading incorrect the gas from a cylinder. -
Page 59: Chapter 7 Parts Replacement
PARTS REPLACEMENT The operations in this chapter should be performed only by quali- fied service personnel. There are no operator-serviceable components inside the CG1100, and an operator should never open the cover of the analyzer. This appendix shows you how to replace system parts and is divided into the following sections: • Cell Assembly Replacement • Thermocouple Replacement... -
Page 60: Cell Replacement
Cell Replacement Removing the Cell Assembly Turn the three-way valve on the back of the CG1100 to OFF. Disconnect the 24 VDC power connector from the analyzer. Allow the analyzer to cool down at least 15 minutes before proceeding. Loosen the four (4) Swagelok nuts and remove the U-shaped tubing. Always use a backup wrench when working on sensor plumbing. -
Page 61: Installing The New Cell
O-ring that comes with the kit. You will be using the white Chem-Raz O-ring. Take the Chem-Raz O-ring and apply a small amount of the grease (AMETEK P/N 06058JE) that comes with the kit, and slide it over the open end of the new cell until it is midway be- tween the white band and the open end. -
Page 62: Replacing The Cell Assembly
Replacing the Cell Assembly Locate the cell clip and attach it to the cell assembly on the plati- num portion of the sensor a short distance from the ceramic por- tion (Figure 7-3). Make sure that the entire cell clip is on the plati- num. -
Page 63: Furnace Replacement
Furnace Replacement Make sure that the power source has been disconnected from the analyzer when servicing system components. High voltages are present inside the analyzer when power is applied. The furnace is hot, even after power has been disconnected from the analyzer. -
Page 64: Installing The New Furnace
Loosen the captive screw on the furnace L-bracket until the furnace is loosened from the L-bracket (see Figure 7-4). Pull the furnace straight up and remove through the top of the analyzer. Installing the New Furnace Retrieve the new furnace (74260KE) and thermocouple assembly (25565JE). -
Page 65: Replacing The Boards
Replacing the Boards LED Board Removing the LED board Disconnect the top (6-connector) ribbon cable. See Figure 7-7. Disconnect the bottom (9-connector) cable. See Figure 7-7. Using a Philips screwdriver, remove the four screws holding the LED board onto the front of the unit. The bottom right-hand screw may be difficult to get at. -
Page 66: Analog Board
Analog Board Removing the analog board The analog board has a total of eight cable/connectors attached to the board. Please make note of the position of the cables before removing and use the drawing in Figures 7-6 and 7-10 as a reference. NOTE Remove the 9-connector LED ribbon cable (J2) from the upper right- hand corner of the analog board. - Page 67 Remove the 2-position Furnace connector (TB6) from the upper left- hand side of the board. Remove the 2-position Cell connector (TB4) from the left-hand side of the board. Remove the 2-position Thermocouple connector (TB5) from the left- hand side of the board. Remove the 5-position Mass Flow ribbon cable (J4) from the front of the board.
- Page 68 MCU Board Removing the MCU board Follow the instructions for removing the analog board. Disconnect the 10-position RS-232 ribbon cable (P4) on the left-hand side of the MCU board. See Figure 7-9. Disconnect the 10-position RS-485 ribbon cable (P2) on the left-hand side of the MCU board.
- Page 69 LED Cable Power Furnace Cell Thermocouple Mass Flow I / O Figure 7-10. Cable/connector locations on the analog board. Service and Parts | 7-11...
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Page 70: Mass Flow Meter
Mass Flow Meter Removing the mass flow meter Loosen the inside and outside tubing nuts to separate the flow meter from the tubing. See Figure 7-11. Loosen the nut on the outside cover located under the 3-way valve. Gently remove the flow meter from the assembly and unscrew the connectors and save. - Page 71 Reconnect the inside tubing to the other end of the flow meter. Connector Mass Flow Meter Connector Figure 7-12. Mass flow meter, flow direction. Service and Parts | 7-13...
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Page 72: Replacement Parts
Replacement Parts Figure 7-13 lists the replacement parts available for the CG1100 Oxygen Analyzer. Please contact the AMETEK sales office for pricing and ordering information. Part Description AMETEk Part Number Sensor Replacement Kit 74633TE User Manual 90477VE MCU Board 305110901... -
Page 73: Appendix A Communications Protocol
COMMUNICATIONS PROTOCOL Protocol Summary > AAFddddCC[CR] Command A[CR] Acknowledge AddddCC[CR] Acknowledge with data NEE[CR] Error with code Character Function Start flag > Two character Ascii hex node address one character Ascii function code Data field. Up to 240 characters of ASCII data. dddd Two character Ascii hex checksum;... -
Page 74: Addresses
Addresses Addresses F0 through FF are reserved for special functions. In addition address ?? is used as a broadcast address. Address F0 Node address F0 is used as a single point address, i.e. it is intended for use in configurations with a single slave. The slave will respond to all mes- sages with node address F0. -
Page 75: Defined Responses (Slave To Master
Defined Responses (slave to master) There are three possible responses to a communication transfer initiated by the master. These are a Simple Acknowledge, Acknowledge with Data, and a Failure message. Simple Acknowledge If the received command does not require data to be returned, a simple acknowledge consisting of an ASCII ‘... -
Page 76: Function Codes
Function Codes The function code is a one character ASCII code in the range ‘ A ’ to ‘Z’ and ‘a’ to ‘z’. Read Data (F) or (R) The data field of this message contains a two-character hex variable ID. The data returned is ID dependent. - Page 77 Calibrate (C) Abort calibration or verify. Start automatic calibration (requires auto cal. option) Start automatic verification (requires auto cal. option) save the cell millivolt reading for the zero gas. save the cell millivolt reading for the span gas. Manually calibrate based on previously saved zero and span mil- livolt readings.
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Page 78: Variables
Variables Variable Name Hex ID Notes Analyzer Type “DYcoR cg1100” serial number software Version Date “01/04/2000” Time “14:36:00” Baud Rate “9600” or “19200” node Address “00” see section 1 serial Mode 0 = two-wire, 1= four-wire Rs-485 Analyzer name 40 character maximum System Status Function 0x0001... - Page 79 Pressure Voltage 0 = Off, 1 = Start auto calibration, 2 = Start auto verification Digital input Mode cell Pressure sample pressure in Psig Zero MV Zero gas cell millivolts span MV span gas cell millivolts Zero gas percent span gas Percent Auto cal Hour Hour: 0 to 23 Auto cal Day...
- Page 80 0 = disabled, 1 = oxygen, 2 = flow, 3 = pressure, 4 = mois- Enable Alarm 1 ture Alarm 1 High Limit Alarm 1 Low Limit 0 = disabled, 1 = oxygen, 2 = flow, 3 = pressure, 4 = mois- Enable Alarm 2 ture, 5 = cg1000 Alarm 2 High Limit...