Emerson Rosemount 880A NDIR Gas Analyzer Instruction Manual

Instruction Manual 748250-N June 2002 Model 880A Non-Dispersive Infrared Analyzer http://www.processanalytic.com ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation. • Read all instructions prior to installing, operating, and servicing the product. • If you do not understand any of the instructions, contact your Rosemount Analytical representative for clarification. • Follow all warnings, cautions, and instructions marked on and supplied with the product. • Inform and educate your personnel in the proper installation, operation, and maintenance of the product. • Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources. • To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product. • When replacement parts are required, ensure that qualified people use replacement parts specified by Rosemount. Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation. • Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury. The information contained in this document is subject to change without notice. Teflon and Viton are registered trademarks of E.I. duPont de Nemours and Co., Inc. Irtran is a trademark of Eastman Kodak Co. Pyrex is a registered trademark of Corning Glass Works SNOOP is a registered trademark of NUPRO Co. Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com http://www.processanalytic.com Instruction Manual 748250-N June 2002 Model 880A TABLE OF CONTENTS PREFACE...........................................................................................................................................P-1 Definitions ...........................................................................................................................................P-1 Safety Summary .................................................................................................................................P-2 General Precautions For Handling And Storing High Pressure Gas Cylinders .................................P-4 Documentation....................................................................................................................................P-5 Compliances .......................................................................................................................................P-5 1-0 1-1 1-2 1-3 DESCRIPTION AND SPECIFICATIONS..............................................................................1-1 General Description...............................................................................................................1-1 Options ..................................................................................................................................1-1 Specifications ........................................................................................................................1-3 2-0 2-1 2-2 2-3 2-4 INSTALLATION ....................................................................................................................2-1 Unpacking..............................................................................................................................2-1 Location .................................................................................................................................2-1 Voltage requirements ............................................................................................................2-1 Electrical Connections ...........................................................................................................2-1 a. Line Power Connections .................................................................................................2-1 b. Recorder Connections ....................................................................................................2-3 Sample Connections .............................................................................................................2-3 Calibration Gas Requirements ..............................................................................................2-3 sample handling system ........................................................................................................2-3 Leak Test Procedure .............................................................................................................2-4 Sample Flow Rate .................................................................................................................2-4 Option Boards........................................................................................................................2-6 a. Alarm Connections..........................................................................................................2-6 b. Calibration Gas Control Connections..............................................................................2-6 c. Current Output Connections ...........................................................................................2-7 d. Auto Zero/Span Connections..........................................................................................2-8 e. Remote Input/Output Connections..................................................................................2-9 Ordering Option Kits ..............................................................................................................2-10 Motor Source/Reference Cell Purge Kits ..............................................................................2-10 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 3-0 3-1 3-2 3-3 3-4 3-5 OPERATION .........................................................................................................................3-1 Leak Test ...............................................................................................................................3-1 Power Verification..................................................................................................................3-1 Front Panel Indicators and Controls......................................................................................3-2 a. Display ............................................................................................................................3-2 b. Function Keys .................................................................................................................3-2 c. User-Programmable Keys...............................................................................................3-3 d. Run Mode Display...........................................................................................................3-4 e. General Display Information ...........................................................................................3-4 Accessing Mode Displays......................................................................................................3-5 Security Code ........................................................................................................................3-5 Rosemount Analytical Inc. A Division of Emerson Process Management Contents i Instruction Manual 748250-N June 2002 3-6 3-12 3-13 3-14 3-15 3-16 3-17 3-18 Range Parameters ................................................................................................................3-8 a. Range Selection..............................................................................................................3-8 b. Component of Interest ....................................................................................................3-8 c. Gain.................................................................................................................................3-8 d. Range, Fullscale .............................................................................................................3-9 e. Calibration Gas ...............................................................................................................3-9 f. Zero Offset ......................................................................................................................3-9 g. Time Constant.................................................................................................................3-9 Analyzer Diagnostics .............................................................................................................3-9 Zero Calibration .....................................................................................................................3-9 Span Calibration ....................................................................................................................3-10 Linearization ..........................................................................................................................3-12 a. All Range.........................................................................................................................3-13 b. Non-Standard Ranges and Coefficients .........................................................................3-13 Alarm .....................................................................................................................................3-15 a. STATUS Display .............................................................................................................3-16 Current Output.......................................................................................................................3-17 Zero/Span Calibration With Calibration Gas Control.............................................................3-17 Auto Zero/Span .....................................................................................................................3-18 Remote Range Input/Output..................................................................................................3-21 Routine Operation .................................................................................................................3-23 Recommended Calibration Frequency..................................................................................3-23 Shutdown...............................................................................................................................3-23 4-0 4-1 THEORY................................................................................................................................4-1 Detection System Theory ......................................................................................................4-1 5-0 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 TROUBLESHOOTING ..........................................................................................................5-1 Error Code Summary.............................................................................................................5-1 Voltage Checks .....................................................................................................................5-2 Oscillator Tune Adjustment ...................................................................................................5-2 Preamp Gain .........................................................................................................................5-2 Digital GAIN Adjustment........................................................................................................5-2 Source Balance Shutter Adjustment .....................................................................................5-3 Source Alignment ..................................................................................................................5-6 Source Current Adjustment ...................................................................................................5-6 Case Heater Temperature Control ........................................................................................5-6 ERL Error Message ...............................................................................................................5-6 6-0 6-1 ROUTINE SERVICING..........................................................................................................6-1 Cell Removal, Cleaning and Installation................................................................................6-1 a. Long Cell Configurations.................................................................................................6-1 b. Short Cell Configurations ................................................................................................6-2 Cell Desiccant........................................................................................................................6-4 Source Replacement .............................................................................................................6-4 Source Balance Shutter Adjustment .....................................................................................6-4 Chopper Motor Assembly ......................................................................................................6-4 a. Long Cell Configurations.................................................................................................6-4 b. Short Cell Configurations ................................................................................................6-5 Micro Board Replacement .....................................................................................................6-6 3-7 3-8 3-9 3-10 3-11 6-2 6-3 6-4 6-5 6-6 ii Model 880A Contents Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A 6-7 6-8 Detector Replacement...........................................................................................................6-6 a. Removal - Long Cell Configurations ...............................................................................6-6 b. Removal - Short Cell Configurations...............................................................................6-6 c. Detector Installation ........................................................................................................6-7 Electronic Circuitry.................................................................................................................6-9 a. Oscillator Circuit Board and Associated Elements of Amplitude-Modulation Circuit ......6-9 b. Functioning of Modulation System in TUNE Mode .........................................................6-9 c. Functioning of Modulation System in Operating Mode ...................................................6-9 d. Radio-Frequency Demodulator.......................................................................................6-10 e. Signal Board (DWG 624085) ..........................................................................................6-10 f. Power Supply Board (DWG 655137) ..............................................................................6-10 g. Adapter Board (DWG 624127)........................................................................................6-10 h. Micro Board (DWG 623782) ...........................................................................................6-10 i. Case Heater Temperature Control Board (DWG 624003) .............................................6-11 j. Dual Alarm/Calibration Gas Control Board (DWG 624204)............................................6-11 k. Isolated Remote Input/Output Board (DWG 624251) .....................................................6-11 l. Auto ZERO/SPAN Board (DWG 624599) .......................................................................6-11 m. Current Output Board (DWG 624092) ............................................................................6-11 n. Auto Range Change .......................................................................................................6-11 7-0 7-1 7-2 REPLACEMENT PARTS ......................................................................................................7-1 Circuit Board Replacement Policy.........................................................................................7-1 Selected Replacement Parts .................................................................................................7-1 a. Model 880A Common Parts............................................................................................7-1 b. Case Heater Temperature Control Assembly (Option)...................................................7-1 c. Optical Bench..................................................................................................................7-1 8-0 8-1 8-2 8-3 RETURN OF MATERIAL ......................................................................................................8-1 Return Of Material .................................................................................................................8-1 Customer Service ..................................................................................................................8-1 Training..................................................................................................................................8-1 Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii Instruction Manual 748250-N June 2002 Model 880A LIST OF ILLUSTRATIONS Figure 1-1. Figure 2-1. Figure 2-2. Figure 2-3. Figure 2-4. Figure 2-5. Figure 2-6. Figure 2-7. Figure 2-8. Figure 3-1. Figure 3-2. Figure 3-3. Figure 3-4. Figure 3-5. Figure 3-6. Figure 3-7. Figure 3-8. Figure 3-9. Figure 3-10. Figure 3-11. Figure 3-12. Figure 3-13. Figure 3-14. Figure 3-15. Figure 5-1. Figure 5-2. Figure 6-1. Figure 6-2. Figure 6-3. Figure 7-1. Figure 7-2. Figure 7-3. Model 880A Detection System .............................................................................. 1-1 Cable Gland ........................................................................................................... 2-1 Power Supply Board .............................................................................................. 2-2 Case Heater Temperature Control Board.............................................................. 2-2 Rear View of Model 880A ...................................................................................... 2-5 Calibration Gas Control and Alarm Connections................................................... 2-6 Current Output Connections .................................................................................. 2-7 Auto Zero/Span Board Connections...................................................................... 2-8 Remote Input/Output Board Connections.............................................................. 2-9 Model 880A Component and Adjustment Locations ............................................. 3-1 Model 880A Keypad .............................................................................................. 3-2 Run Mode Display ................................................................................................. 3-4 Logic Flow Diagram ............................................................................................... 3-6 Security Mode Flow Diagram................................................................................. 3-7 Range Mode Flow Diagram ................................................................................... 3-8 Diagnostic Mode Flow Diagram........................................................................... 3-11 Linearizer Mode Flow Diagram............................................................................ 3-12 Typical Application Linearization Curve, Linearizer OFF .................................... 3-14 User Determined Linearization Curve (Normalized)............................................ 3-14 Alarm Mode Flow Diagram .................................................................................. 3-15 Status Display ...................................................................................................... 3-16 Current Output Mode Flow Diagram.................................................................... 3-17 Auto Zero/Span Flow Diagram ............................................................................ 3-20 Remote Input/Output ........................................................................................... 3-21 Functional Block Diagrams .................................................................................... 5-4 Modulation System ................................................................................................ 5-5 Optical Bench Cell Replacement ........................................................................... 6-3 Motor/Source Assembly......................................................................................... 6-5 Detector Replacement ........................................................................................... 6-8 Model 880A Assembly ........................................................................................... 7-2 Case Heater Temperature Control Assembly........................................................ 7-3 Optical Bench Assembly........................................................................................ 7-4 LIST OF TABLES Table 2-1. Table 3-1. Table 3-2. Table 5-1. Table 6-1. Table 6-2. iv Contents Purging Time at Atmospheric Sample Pressure.................................................... 2-5 Remote Range I/O Designation........................................................................... 3-22 Remote Range I/O Binary and Decimal Coding .................................................. 3-22 Error Code Summary............................................................................................. 5-1 Types of Desiccant ................................................................................................ 6-4 Jumper Configurations for Option Boards ........................................................... 6-12 Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A LIST OF DRAWINGS (LOCATED IN REAR OF MANUAL) 623782 623995 624003 624085 624092 624127 624190 624204 624251 624599 655137 655147 Schematic Diagram, Microprocessor Board Schematic Diagram, Oscillator Board Schematic Diagram, Temperature Control Board Schematic Diagram, Signal Board Schematic Diagram, Isolated Voltage to Current Board Schematic Diagram, Adapter Board Installation Drawing, Model 880A Schematic Diagram, Dual Alarm/Fail Safe Alarm Schematic Diagram, Isolated Remote Control Board Schematic Diagram, Auto Zero/Span Board Schematic Diagram, Power Supply Board Pictorial Wiring Diagram, Model 880A Calibration Data Sheet Rosemount Analytical Inc. A Division of Emerson Process Management Contents v Instruction Manual 748250-N June 2002 vi Contents Model 880A Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A PREFACE The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the Model 880A. Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely. DEFINITIONS The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout this publication. DANGER . Highlights the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored. WARNING . Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel. CAUTION. Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness. NOTE Highlights an essential operating procedure, condition or statement. Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1 Instruction Manual 748250-N June 2002 Model 880A SAFETY SUMMARY If this equipment is used in a manner not specified in these instructions, protective systems may be impaired. AUTHORIZED PERSONNEL 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 this equipment should be thoroughly familiar with and strictly follow the instructions in this manual. SAVE THESE INSTRUCTIONS. DANGER. 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. Alarm and zero/span switching relay contacts wired to separate power sources must be disconnected before servicing. This instrument is shipped from the factory set up to operate on 115 volt, 50/60 Hz electric power. For operation on 230 volt, 50/60 Hz power, see Section 2-3 (page 2-1) for modifications. WARNING. PARTS INTEGRITY Tampering or unauthorized substitution of components may adversely affect safety of this product. Use only factory documented components for repair. WARNING HIGH PRESSURE GAS CYLINDERS This analyzer requires periodic calibration with known zero and standard gases. Refer to Sections 2-6, 3-8, 3-9, 3-10, and 3-11. See also General Precautions for Handling and Storing High Pressure Cylinders, , page P-4. P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A WARNING. POSSIBLE EXPLOSION HAZARD This analyzer is of a type capable of analysis of sample gases which may be flammable. If used for analysis of such gases the instrument must be protected by a continuous dilution purge system in accordance with Standard ANSI/NFPA 496-1989, Chapter 8. If explosive gases are introduced into this analyzer, the sample containment system must be carefully leak-checked upon installation and before initial startup, during routine maintenance and any time the integrity of the sample containment system is broken, to ensure the system is in leak-proof condition. Leak-check instructions are provided in Section 2-8, page 2-4 Internal leaks resulting from failure to observe these precautions could result in an explosion causing death, personal injury or property damage. CAUTION TOPPLING HAZARD This instrument’s internal pullout chassis is equipped with a safety stop latch located on the left side of the chassis. When extracting the chassis, verify that the safety latch is in its proper (counter-clockwise) orientation. If access to the rear of the chassis is required, the safety stop may be overridden by lifting the latch; however, further extraction must be done very carefully to insure the chassis does not fall out of its enclosure. If the instrument is located on top of a table or bench near the edge, and the chassis is extracted, it must be supported to prevent toppling. Failure to observe these precautions could result in personal injury and/or damage to the product. Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3 Instruction Manual 748250-N June 2002 Model 880A GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed Gases" published in 1981 Compressed Gas Association 1235 Jefferson Davis Highway Arlington, Virginia 22202 Used by Permission 1. Never drop cylinders or permit them to strike each other violently. 2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when located in areas where extreme temperatures are prevalent. 3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or placed in a cylinder stand, and is ready to be used. 4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a suitable hand-truck. 5. Never tamper with safety devices in valves or cylinders. 6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is attached to a pressurized system. 7. No part of cylinder should be subjected to a temperature higher than 125°F (52°C). A flame should never be permitted to come in contact with any part of a compressed gas cylinder. 8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, precautions must be taken to prevent striking an arc against the cylinder. P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A DOCUMENTATION The following Model 880A instruction materials are available. local representative to order. Contact Customer Service Center or the 748250 Instruction Manual (this document) COMPLIANCES Model 880A Non-Dispersive Infrared Analyzers, Catalog Numbers 191811 (Standard) and 191812 (Extended) when installed with optional Type Z Purge Kit P/N 624446 for use in indoor Class I, Division 2, Groups B, C, and D hazardous locations and for use in indoor non-hazardous locations when sampling flammable gases. When installed without purge kit option, this equipment is intended for sampling only non-flammable gases in non-hazardous locations. This product may carry approvals from a certifying agency or may be in compliance with EMC Directive. If so, the product will carry approval insignia, like those shown here, on the product name rating plate. FM APPROVED 97-C209 Rosemount Analytical Inc. has satisfied all obligations from the European Legislation to harmonize the product requirements in Europe. This product complies with the standard level of NAMUR EMC. Recommendation (May 1993). NAMUR This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New Zealand. N96 Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5 Instruction Manual 748250-N June 2002 P-6 Preface Model 880A Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A SECTION 1 DESCRIPTION AND SPECIFICATIONS A linearizer, based on a fourth-order polynomial, is incorporated in the electronic circuitry. By turning the linearizer ON and entering the correct coefficients, an output linear with concentration is obtained. 1-1 GENERAL DESCRIPTION The Model 880A Non-Dispersive Infrared Analyzer is designed to continuously determine the concentration of a particular component of interest in a flowing gaseous mixture. Within the analyzer, two equal energy infrared beams are directed through two parallel optical cells, a flow-through sample cell and a reference cell. The Luft detector continuously measures the difference in the amount of infrared energy absorbed within each of the two cells. This difference is a measure of the concentration of the component of interest in the sample. 1-2 OPTIONS Readout is on the 16-character, backlighted liquid crystal display in parts per million, percent of composition or percent of fullscale. Additionally, a 0 to +5 VDC output for a potentiometric (voltage) recorder is provided as standard. INFRARED SOURCE Operation of the Model 880A can be enhanced with the choice of several options: Dual Alarms (standard and fail-safe) User-set dual alarms are available with configurable HI/LO designations and deadband. Current Output For normal usage, the 0/4 to 20 mA current output can be set to represent 0 to 100% of fullscale, or a suppressed range of 25% or more of fullscale may be selected. CHOPPER SAMPLE IN SAMPLE CELL REFERENCE CELL SAMPLE OUT DIAPHRAGM DISTENDED DETECTOR STATIONARY BUTTON SIGNAL SIGNAL CONDITIONING CIRCUITRY COMPONENT OF INTEREST OTHER MOLECULES Figure 1-1. Model 880A Detection System Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1 Instruction Manual 748250-N June 2002 Auto Zero/Span Purge Kits An Automatic Zero/Span is available for unattended calibration of all three ranges. An air purge kit, when installed with user-supplied components, meets Type Z requirements of standard ANSI/NFPA 496-1989 for installation in Class I, Division 2 locations as defined in the National Electrical Code (ANSI/NFPA 70) when sampling nonflammable gases. If analyzer is used to sample a flammable gases it must be protected by a continuous dilution purge system per standard ANSI/NFPA 496-1989, Chapter 8. Consult factory for further information. Calibration Gas Control A Calibration Gas Control allows two solenoids to be remotely actuated from the front panel, enabling one-man calibration without leaving the analyzer. Remote Range Selection and ID A remote range change and ID is available. Case Heater A proportional temperature controller with fan assembly maintains proper operating temperature inside the case. 1-2 Model 880A Description and Specifications A motor source or motor source/reference cell purge kit accompanies some configurations of the Model 880A. The purpose for these kits is reduction of ambient CO2 interference and, thus, improved performance and accuracy. These purges do not provide explosion hazard protection. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A 1-3 SPECIFICATIONS Power Requirements..................... 115/230 VAC ±10%, 50/60 ±3 Hz, 350 W Operating Temperature ................. 32°F to 113°F (0°C to 45°C) Dimensions.................................... 8.7 in (22.0 cm) H 19 in. (48.3 cm) W 19 in. (48.3 cm) D, standard case 24 in. (61.0 cm) D, extended case Weight ........................................... 56 lbs (25 kg), standard case 68 lbs (31 kg), extended case Repeatability.................................. 1% of fullscale Noise ............................................. 1% of fullscale Zero Drift1 ...................................... ±1% of fullscale per 24 hours; ±2% of fullscale per week Span Drift1 ..................................... ±1% of fullscale per 24 hours; ±2% of fullscale per week Response Time (Electronic) .......... Variable, 90% of fullscale in 0.5 sec to 20 sec, field selectable. (Application dependent) Sensitivity ...................................... 100 ppm fullscale carbon monoxide at atmospheric pressure 50 ppm fullscale carbon dioxide at atmospheric pressure Sample Cell Length ....................... 0.04 in. (1 mm) to 14.0 in. (381 mm) Materials in Contact with Sample Windows.................... Sapphire, quartz, Irtran Cells .......................... Gold plated Pyrex or stainless steel Tubing ....................... FEP Teflon Fittings....................... 316 stainless steel O-Rings ..................... Viton-A Sample Pressure2.......................... Max 10 psig (69 kPa), standard Analog Output Standard ................................ 0 to 5 VDC Optional ................................. 0 to 20 mA/4 to 20 Ma Linearization .................................. Keypad entered coefficients for linearizing 1, 2 or all 3 ranges Enclosure....................................... General purpose for installation in weather-protected area. Optional purge kit per Type Z, ANSI/NFPA 496-1989.3 1 Performance specifications based on ambient temperature shifts of less than 20°F (11°C) per hour. Pressurized application available upon request 3 When installed with user-supplied components, meets requirements for Class I, Division 2 locations per National Electrical Code (ANSI/NFPA 70) for analyzers sampling non-flammable gases. Analyzers sampling flammable gases must be protected by a continuous dilution purge system in accordance with Standard ANSI/NFPA 496-1989, Chapter 8. Consult factory for recommendations. 2 Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3 Instruction Manual 748250-N June 2002 1-4 Description and Specifications Model 880A Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A SECTION 2 INSTALLATION 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 material until the instrument is operational. 2-2 LOCATION Locate the analyzer in a weather-protected, non-hazardous location free from vibration. For best results mount the analyzer near the sample stream to minimize sample-transport time. Refer to Installation Drawing 624190. If equipped with P/N 624446 air purge kit and installed with user-provided components per Instructions 015-748157, the analyzer may be located in a Class I, Division 2 area as defined by the National Electrical Code (ANSI/NFPA 70). This kit is designed to provide Type Z protection in accordance with Standard ANSI/NFPA 496-1989, Chapter 2, when sampling nonflammable gases. For flammable samples, the instrument must be equipped with a continuous dilution purge system in accordance with ANSI/NFPA 496-1989, Chapter 8. 2-3 VOLTAGE REQUIREMENTS WARNING ELECTRICAL SHOCK HAZARD For safety and proper performance, this instrument must be connected to a properly grounded three-wire source of electrical power. This instrument was shipped from the factory configured to operate on 115 VAC, 50/60 Hz electric power. For operation on 230 VAC, 50/60 Hz, voltage select switches S1, S2, Rosemount Analytical Inc. A Division of Emerson Process Management located on Power Supply Board Figure 2-2 (page 2-2) and, if installed, S3, located on the Case Heater Temperature Control Board Figure 2-3 (page 2-2) must be in the 230 VAC position. Power consumption is 350 watts. Ref Figure 7-2, page 7-3 2-4 ELECTRICAL CONNECTIONS The power, recorder and current output cable glands are shipped already installed to allow attachment of cables to connectors or terminal strips. Cable glands for specific cables are as follows: Cable Power Recorder Option Board Gland Part No. 899330 899329 899329 Remove the rear cover to access the terminals. Route each cable through the cable gland and connect to appropriate connector or terminal strip, tighten the gland. a. Line Power Connections Refer to Figure 2-3, Figure 2-4 and drawing 624190. If this instrument is located on a bench or table top or is installed in a protected rack, panel or cabinet, power may be connected via a 3-wire flexible power cord, minimum 18 AWG (max. O.D. 0.480", min. O.D. 0.270") through hole labeled POWER, utilizing connector gland (P/N 899330) provided. INTERIOR Nut EXTERIOR Gland Nut Cable Case Wall Figure 2-1. Cable Gland Installation 2-1 Instruction Manual 748250-N June 2002 Model 880A Accessory kits are available which include one of the following: 1) a 10-foot North American power cord set and four enclosure support feet (P/N 654008) for bench top use, 2) the power cord only (P/N 634061), or 3) the four feet only (P/N 634958). If the instrument is permanently mounted in an open panel or rack, use electrical metal tubing or conduit. Route the power cable through the cable gland and connect the leads to TB1. After connecting the leads, tighten the cable gland adequately to prevent rotation or slippage of the power cable. Since the rear terminals do not slide out with the chassis, no excess power cable slack is necessary. Set switch windows for voltage required S2 S1 TP1 TP2 SS R34 R8 R35 R4 R5 R36 R13 AR4 R37 R10 LUFT R12 R9 R3 S3 C19 U2 R39 R18 R6 J 10 Q4 R7 8 S2 230V 2 6 3 5 115V DETECTOR HEATER TEMP CONTROL CASE J2 J5 J4 1 VR4 VR2 I G + I + CR3 + VR3 VR1 G I R11 + K1 1 4 3 2 + + C5 C7 R24 J15 + G O + C9 + O CR6 CR7 + CR2 C1 1 I 1 B Q2 C15 C CR1 J8 J11 R25 R29 R26 E - 1 R14 C10 C3 R17 R32 C11 + + 1 CR8 R30 R27 R28 + O R15 C20 C16 R31 + 1 J16 U1 C6 C8 G O C2 1 J14 R 38 C12 + CR4 FAN C21 AR5 4 + + R16 AR1 C4 115 R19 C18 R20 S1 115 C14 C13 1 7 R23 1 A G R21 R33 C R22 B R1 R2 K Q1 1 J13 Q3 E CR5 655135 POWER SUPPLY BD J7 1 Heater LED (CR5) Figure 2-2. Power Supply Board Set switch window for voltage required S3 SENSOR POWER SUPPLY J11 J18 400A 880 951E POWER LINE J5 C4 C2 R10 R11 R7 R8 R17R16 R12CR2 R15 R6 1 3 2 C3 U2 1 C1 R1 R2 R3 K C Q2 + 1 1 2 1 2 3 CR3 Q1 G E B R13 3 S3 230 R9 R5 1 R4 2 U1 AR1 CR1 1 R14 115 E B A C Q3 J19 TEST T.I.F. HEATER J17 115 TEMP CONTROL BD Figure 2-3. Case Heater Temperature Control Board 2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A b. Recorder Connections Refer to Figure 2-1 (page 2-1), Figure 2-4 (page 2-5) and drawing 624190. Recorder connections are made to the rear panel. Route the recorder cable through the cable gland in hole labeled RECORDER OUTPUT and connect to TB2. Recorder and interconnection cables should meet the following requirements: are located on the rear panel. All connections are 1/4-inch ferrule-type compression fittings. 2-6 CALIBRATION GAS REQUIREMENTS Analyzer calibration consists of setting a zero point and one upscale point per range. All applications require a zero standard gas to set the zero point on the display or recorder chart. • Maximum distance from recorder to analyzer: 1000 ft. (305 m) If the factory Calibration and Data Sheet (in the rear of the manual) specifies a background gas, use this as the zero gas. If a background gas is not specified, use dry nitrogen for the zero gas. • Recorder input impedance: >5000 ohms Ideally, span gas should be between 75% and 100% of the fullscale span. • Customer-supplied cable: 2-conductor, 20 AWG (min.), shielded • Current Output: 0 to 20 mA or 4 to 20 mA (keyboard programmable) • Maximum load impedance: 700 ohm Voltage Output: 0 to +5 VDC 2-5 SAMPLE CONNECTIONS Most applications of the Model 880A are intended for atmospheric pressure operation with venting to the atmosphere. High pressure and sub-atmospheric pressure applications require careful regulation of the sample pressure. Sample inlet and outlet connections Rosemount Analytical Inc. A Division of Emerson Process Management 2-7 SAMPLE HANDLING SYSTEM Many different sample handling systems are available, either assembled completely or as loose components. The type used depends on the requirements of the particular application and the preferences of the individual user. Typically, the sample handling system incorporates such components as pumps and valves to permit selection of sample, zero standard and upscale standard gas; needle valve in sample-inlet line for flow adjustment; flowmeter for flow measurement and/or indication of flow stoppage; and filter(s) to remove particulate matter. Installation 2-3 Instruction Manual 748250-N June 2002 Model 880A NOTE 2-8 LEAK TEST PROCEDURE WARNING POSSIBLE EXPLOSION HAZARD This analyzer is of a type capable of analyzing sample gases which may be flammable. If used for analysis of such gases the instrument must be protected by a continuous dilution purge system in accordance with Standard ANSI/NFPA 4961989, Chapter 8. If explosive gases are introduced into this analyzer, the sample containment system must be carefully leak-checked upon installation and before initial startup, during routine maintenance and any time the integrity of the sample containment system is broken, to ensure the system is in leakproof condition. Internal leaks resulting from failure to observe these precautions could result in an explosion causing death, personal injury or property damage. To check for leaks in the sample system, do the following: 1. Supply air or inert gas such as nitrogen to the sample inlet of the analyzer at 10 psig (69 kPa). 2. Seal off sample outlet with a cap, and turn off supply of inert gas. After 1 hour, pressure reading should not drop. If it does, the system is leaking. Continue with steps 3 thorough 4 to locate source of leak. 3. Use a suitable test liquid such as SNOOP (P/N 837801) to detect leaks. Cover all fittings, seals or possible leak sources. 4. Check for bubbling or foaming which indicates leakage and repair as required. Any leakage must be corrected before introduction of sample and/or application of electrical power. Apply test liquid to cell or detectors and IR source windows only as a last resort. Should this occur, follow instructions in Section 6-1 (page 6-1) clean these components. 2-9 SAMPLE FLOW RATE Recommended sample flow rate is 1 to 2 SCFH (500 to 1000 cc/min). A subnormal flow rate will not affect readings but may result in an undesirable time lag. However, an excessive flow rate can result in cell pressurization and reading error. Assume that two cell volumes are required to flush any cell. Approximate flushing time for the Model 880A's 12-inch cell at atmospheric sampling pressure (i.e., the outlet of the cell venting to atmosphere) is approximately 12 seconds. Flushing time decreases with cell volume (see Table 2-1, page 2-5). Flushing time is inversely proportional to flow rate. The primary effect of flow rate, other than flushing time, is cell pressure. Due to restrictions in exit flow configuration, an increasing flow rate increases sample pressure in the cell. In all cases, the effect of pressure on readout is eliminated if the same flow rate is used for the measured sample as well as for the zero gas and span gas. Note that at higher flow rates the non-linearity of the calibration curve increases, because of increase in sample cell pressure. Therefore, if higher flow rates are required, the calibration curve should be redrawn at the higher rate. At flows up to 2 CFH (1 L/min), gaseous sample temperatures are equilibrated to instrument temperature regardless of stream temperature. At extremely high flow rates, this may not be true, but no such effect has been noted up to 18 CFH (9 L/min). 5. For smaller leaks, use a Halogen or helium leak detection device. 2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A CELL LENGTH mm inch 3 4 8 16 32 64 128 232 343 381 CELL VOLUME IN CC Without Inlet Tube TOTAL VOLUME IN CC Cell with Inlet Tube 0.85 1.14 2.28 3.56 9.12 18.24 35.48 65.12 97.76 108.60 12 12 13 16 20 25 44 73 105 116 0.118 0.157 0.315 0.630 1.25 2.52 4.03 9.13 13.50 15.00 Table 2-1. PURGE GAS OUTLET REFERENCE OUT IN TIME FOR 2 VOLUMES AT 2 SCFH (1 L/MIN) at 750 mm Hg 2 sec. 2 sec. 2 sec. 2 sec. 2 sec. 3 sec. 3 sec. 6 sec. 13 sec. 14 sec. Purging Time at Atmospheric Sample Pressure SAMPLE OUT IN OPTIONS CONNECTIONS RECORDER OUTPUT PURGE GAS IN POWER Power Hook-UP TB1 GND F1 4A RESETTABLE CIRCUIT BREAKER + NEUT/L2 - GND HOT/L1 TB2 Auto Zero/Span Control Board Isolated V/I Board Dual Alarm Board Isolated Remote Control Board Calibration Gas Control Board Recorder Output Hook-Up OPTION BOARDS INSTALLED WITH COMPONENT SIDE TO THE LEFT. Figure 2-4. Rear View of Model 880A Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5 Instruction Manual 748250-N June 2002 Model 880A a. 2-10 OPTION BOARDS Alarm Connections Refer to Figure 2-1 (page 2-1), Figure 2-5 below and drawing 655147. Connect cable (customer supplied) to the 6-pin connector J2. The Dual Alarm consists of two form C contacts rated 3A-125/250 VAC or 5A-30 VDC (resistive). The following option boards may be ordered factory installed or as kits from the factory at a later date: Alarm, Current Output, Calibration Gas Control, Auto Zero/Span and Remote Range I/O. The boards are supplied with outlet connector mating plugs installed on each board for field wiring. Attach the cable (customer supplied) to the outlet connector plug per the appropriate schematic diagram for each option board. Run the cable through the cable gland and tighten once the connector has been secured. If an option board has been ordered installed at the factory, this board will be inserted into one of five slots inside the rear of the analyzer (See Figure 2-4 page 2-5). Each option will require a cable (user-provided) which connects to a female plug. The female plug, in original packaging, is attached to the appropriate terminal block on the option board. If the instrument came equipped with one option, the interconnect cable will be in place for all options. The Alarm, Auto Zero/Span, Calibration Gas Control and Remote Range Change Boards have jumper-selectable addresses. b. Calibration Gas Control Connections Refer to Figure 2-1 (page 2-1), Figure 2-5 below and Drawing 655147. Connect cable (customer supplied) to the 6-pin connector J2. The Calibration Gas Control consists of two form C contacts rated 3A-125/250 VAC or 5A-30 VDC (resistive). Run the cable through the cable gland and tighten the latter once the connector has been secured. Jumper Selectable Address E4 E2 E1 Outlet Cable B R1 R2 R8 R6 B J2 A Q1 FT2 CR1 A CR2 Q2 C R3 K1 CAL 624419 C T R L 1 1 1 PR1 C U2 B R7 C3 R9 E 10 1 E8 E9 R5 R4 + C1 Interconnect Cable U1 B E C J1 C E FT1 C1 E7 E6 E5 K2 DUAL 624207 A LA R M U3 1 U4 1 FA IL 654398 S A F E A LA R M Note: The Dual Alarm, Fail Safe Alarm and Calibration Gas Control use the same board. However, the jumpers locations are different. Cal Gas Control: E1, E4, E5 - E7 and E9 - E10 Dual Alarm: E1, E2, E5 - E7 and E9 - E10 Fail Safe Alarm: E1, E2, E6 - E7 and E8 - E10 Figure 2-5. Calibration Gas Control and Alarm Connections 2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A c. board has a fixed address at the top of the board. Current Output Connections Refer to Figure 2-1 (page 2-1), Figure 2-6 and Drawing 655147. Connect cable (customer supplied) to the 2-pin connector J2. The voltage-to-current Run the cable through the cable gland and tighten once the connector has been secured. Outlet Cable U1 J2 J1 1 Interconnect Cable 1 1 1 U3 U2 C1 C2 1 O G VR1 I SPAN O FF S E T R2 + R6 R5 R4 R3 O R1 VR2 G I CR1 C8 + AR1 1 I U4 C7 + C3 + C4 C5 C6 624 095 IS O LA T E D V T O I B D Figure 2-6. Current Output Connections Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7 Instruction Manual 748250-N June 2002 d. Model 880A voltage and 0.5 A maximum switching current. Auto Zero/Span Connections Refer to Figure 2-1 (page 2-1), Figure 2-7 below and Drawing 655147. Connect cable (customer supplied) to the 9-pin connectors J2 and J3. The Auto Zero/Span consists of four form C contacts rated 3A-125/250 VAC or 5A-30 VDC (resistive) and two form A contacts rated at 10 watts maximum switching power, 200 VDC maximum switching Run the cable through the cable gland and tighten once the connector has been secured. If installed, this board can also be activated from the keyboard (Zero/Span) for the selected range. Jumper Selectable Address Outlet Cable J2 FT1 K1 FT4 B K4 C C E Q1 Q4 B E4 E2 E1 E C2 C1 J1 1 + FT2 K2 CR1 R4 B C E Q2 K5 R1 B C Q5 CR4 R7 Interconnect Cable R2 E R3 C3 U1 CR2 R5 FT3 K3 B C Q1 E K6 C R 5 R 8 R 10 1 R P 11 B C E Q1 1 1 U4 U2 U3 J3 CR3 R6 1 Figure 2-7. Auto Zero/Span Board Connections 2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A e. voltage and 0.5 A maximum switching current. Remote Input/Output Connections Refer to Figure 2-1 (page 2-1), Figure 2-8 below and Drawing 655147. Connect cable (customer supplied) to the 9-pin connectors J2 and J3. The signal input is at J3 which consists of eight optocouplers, operated from a user-supplied 24 VDC power source. The signal output is at J2 which consists of eight form A contacts rated (resistive load) 10 watts, maximum switching power, 200 VDC maximum switching Run the cable through the cable gland and tighten once the connector has been secured. Jumper Selectable Address J2 E5 E6 E7 Outlet Cable E4 C R 1 R 13 R 11 E8 R2 E2 R1 E1 C1 C5 U7 E9 C3 U1 K1 K5 K2 K6 K3 1 RP2 C4 1 K7 U2 + 1 J1 Interconnect Cable R 12 U3 1 C2 K4 K8 U4 1 J3 R3 R7 R4 R8 R5 R9 R6 R 10 X 624254 U6 1 RP1 1 U5 1 654416 IS O LA T E D R E M O T E C O N T R O L B D Figure 2-8. Remote Input/Output Board Connections Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9 Instruction Manual 748250-N June 2002 Model 880A 2-11 ORDERING OPTION KITS Options not ordered from the factory at the time of purchase of the Model 880A may be ordered as the following kits: • 624422 Isolated Remote Control Kit • 624423 Dual Alarm Kit • 654399 Fail Safe Dual Alarm Kit • 624424 Auto Zero/Span Control Kit • 624426 Calibration Gas Control Kit • 624425 Current Output Kit The option kit consists of the circuit board, a cable gland and two circuit card guides which are inserted into predrilled holes in the card cage. Mount the option board in the card guides and follow the wiring directions in Section 2-10, page 2-6. There are five connectors on the interconnect cable. Ensure that the appropriate connections are made. 2-12 MOTOR SOURCE/REFERENCE CELL PURGE KITS Model 880A configurations 23 and 26 are often equipped with the Motor Source Assembly Purge Kit (P/N 655095) for reducing CO2 interference. Optimum purge flow is 100 cc/min, optimum pressure is 8 psig. The pressure should not exceed 10 psig. Nitrogen is recommended for the purge gas. If available gas is limited, flow may be reduced, but reading errors become significant below 20 cc/min. At 50 cc/min., errors may exceed 1% of fullscale. The purge uses capillary 634398, tested to 70 cc/min. (±10 cc/min.) at 4 psig. Configuration 46 instruments are equipped with a Motor Source/Reference Cell Purge Kit as standard. For installation of any of the above Option Kits, the Option Boards Kit, P/N 624414, must also be ordered. If the analyzer was originally ordered with any of the above options, the Accessory Kit is already installed and need not be ordered again for additional options. This kit consists of a card cage which mounts in the rear of the case and three interconnect cables for internal wiring as shown in drawing 655147. 2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A SECTION 3 OPERATION Prior to shipment this instrument was subjected to extensive factory performance testing, during which all necessary optical and electrical adjustments were made. The following instructions are recommended for initial startup and subsequent standardization of the analyzer. 3-2 POWER VERIFICATION 1. Verify power switch settings are for available power (115 VAC/230 VAC). Refer to Section 2-3 on page 2-1. 2. Apply power. 3-1 LEAK TEST Perform the Leak Test Procedure in Section 2-8 on page 2-4. Source Current Test Point Display Contrast Adjust R8 Reset SW1 3. On the Power Supply Board, verify that heater LED (CR5) is ON. Refer to Figure 3-1 below and Drawing 655137. Source Current Adjust R9 Option Boards Source Balance Adjust and Locknut Power Supply Board Micro Board Gain Adjust R3 Signal Board Motor/Source Detector Module Oscillator Tune Figure 3-1. Model 880A Component and Adjustment Locations Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-1 Instruction Manual 748250-N June 2002 Model 880A ZERO F1 SPAN F2 STATUS MODE SHIFT ENTER Rosemount Analytical Figure 3-2. Model 880A Keypad 3-3 FRONT PANEL INDICATORS AND CONTROLS a. Display The display consists of a 16-character LED-backlighted Liquid Crystal Display. The contrast on the display may be adjusted so that the display can be read from any vertical angle. This adjustment is made by loosening the two screws on the front of the case and sliding the front panel forward, then turning the potentiometer (R8) to adjust the contrast until the best view of the display is obtained. See Figure 3-1 on page 3-1. In the normal RUN mode of operation, the display will show current process value, component name, control mode and range. In other modes, relevant information will be displayed as is necessary. See Figure 3-3 on page 3-4. b. Function Keys The Model 880A has twelve function keys (Figure 3-2 above). Each key must be pressed firmly to insure that the microprocessor recognizes the keystroke. 3-2 The definitions for these keys are as follows: Operation ZERO To activate the manual zero calibration of the analyzer. SPAN To activate the manual span calibration of the analyzer. STATUS To display the configuration and the status of alarms and error messages. Used in conjunction with left and right or up and down arrows, F1, F2 and ENTER keys. Pressing the SHIFT key in any display except Run Mode, Zero Setting, Span Setting and Status causes a ↑ to be displayed at the far right hand position. Pressing → will then move the cursor 16 characters to the right, pressing ← will move the cursor 16 characters to the left, and, if a displayed parameter is being modified, pressing ↑ will access the highest value allowed for that parameter and pressing ↓ will access the lowest value allowed for that parameter. SHIFT Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A momentarily flashing [** DATA STORED **] on the display when used to store a setting in non-volatile memory. Use ENTER to engage the span and zero functions, which are initiated by the SPAN and ZERO keys. Software programmable keys for quick access to mode functions. When used in conjunction with the SHIFT key, two additional functions are available: SHIFT/F1 and SHIFT/F2. The computer acknowledges the keystrokes by flashing [** KEY SAVED **] on the display. These four functions can immediately access a particular display for the following modes: Range, Diagnostics, Linearization, Alarm, Current Output, Auto Zero/Span or Remote Range I/O. Refer to the detailed description in Section 3-3c (page 3-3). F1 F2 [CALCULATING SPAN] or [CALCULATING ZERO] will then be momentarily displayed. The SHIFT key in conjunction with the ENTER key will return to Run Mode from any function screen except: 1) the [CALCULATING ZERO/SPAN] screen and 2) during an auto calibration cycle. SHIFT To display instrument functions. The standard functions are security, range, diagnostics, and linearization. Additional functions, in conjunction with option boards, are Auto Zero/Span, Remote Range I/O, Current Output, and Alarm. MODE The up and down arrow keys are used to modify the data in the display. Depress either the up or down arrow to change the values displayed above the cursor. When used in one of the editing modes, SHIFT ↑ causes the highest value allowed in a function to be displayed. SHIFT ↓ causes the lowest value to be displayed. Depress the arrow key once to change one digit; depress and hold either key to scroll (continuous value change), thereby reducing the time required to make large value changes. To move cursor one position at a time or, when used in conjunction with the SHIFT key moves the cursor 16 characters, one full display, at a time. To access a function, to store a value in nonvolatile memory or to return to run mode from span, zero and security screens. The computer acknowledges ENTER by ENTER Rosemount Analytical Inc. A Division of Emerson Process Management ENTER SHIFT/ENTER during operation of zero and span functions will turn off the appropriate solenoid valve, if connected, for instruments with the Calibration Gas Control or Auto Zero/Span. The SHIFT/ENTER combination is the Escape feature. c. User-Programmable Keys Refer to Figure 3-2, page 3-2. F1, F2, SHIFT/F1 and SHIFT/F2 are software-programmable keys which can be user-programmed to access any frequently used display or sub-menu for the following modes: Range, Diagnostics, Linearization, Auto Zero/Span, Remote Range I/O or Alarm, provided the option board selected is still present. To use this feature, the function keys must be preprogrammed by the user through the following steps: 1. Access a display or sub-menu that will be frequently used by following the steps in the particular set of instructions given in the figures in this section until the desired display is obtained. 2. Press F1, F2, SHIFT/F1 or SHIFT/F2 to program the analyzer to return to Operation 3-3 Instruction Manual 748250-N June 2002 Model 880A this display from the RUN mode. This will assign F1, F2, SHIFT/F1 or SHIFT/F2 to this particular display, and will retain those assignments until the key or combination of keys is reprogrammed using the same procedure described in this section. The analyzer acknowledges this command by flashing [**KEY SAVED**] on the display. d. Run Mode Display The RUN mode is the normal mode of operation. In this mode the display will show current process value component designation, control mode and range. Should an error condition or an alarm condition occur, [ER?] (where ? is an alphanumeric character) or [AL#] (where # is either the number 1 or 2) will flash on the display in the component name location. A list of error messages is located in Section 5-1, page 5-1. Refer to Figure 3-3 below for the different run mode displays. 3. Exit to the RUN mode display by completing the remaining steps in the figure chosen in Step 1. 4. When the analyzer returns to the RUN mode display, press the key or keys selected in Step 2 (F1, F2, SHIFT/F1 or SHIFT/F2) to check the setup. The analyzer will return to the display or sub-menu selected in Step 1. XXX % ABC L1 XXX ppm ABC L2 XXX %FS ER4 R3 5. Press SHIFT/ENTER to return to the RUN mode. NOTE: Concentration Engineering Units, or % Fullscale. If Linearization ON, reads in engineering units. If Linearization OFF, reads in % Fullscale. The programmable keys cannot be assigned to the zero or span screens since these screens are already single-key accessed by the ZERO and SPAN keys, respectively, on the front panel. To reprogram the key or keys selected in Step 2, repeat Steps 1 through 5 for another display or sub-menu. For example, if the GAIN is frequently changed, access the RANGE sub-menu to access the GAIN display and press the F1 key. Press SHIFT/ENTER to return to the RUN mode. To get to the GAIN display from the RUN mode display, press the F1 key. To reprogram the F1 key, go to another display other than the RUN mode display and press the F1 key. This will reprogram the F1 key to the new display. 3-4 Operation Figure 3-3. e. Code for measured component or Error Message Local, or Remote Control, Range 1, 2 or 3. Run Mode Display General Display Information The following features are present to the right of all display sequences (except Run Mode display, Zero/Span screens, Status screen, and Auto Zero/Span screens): → The beginning of a sub-menu is indicated by → in the extreme right position of the display. This arrow indicates that there will be more information in subsequent displays which can be obtained by either pressing the → key until the next display is obtained, or pressing SHIFT → to move 16 characters, one full display, at a time. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A → ← Indicates that there are subsequent displays which can be accessed by pressing the → key to view a new display or the ← key to return to a previous display. To move 16 characters, one full display at a time, press SHIFT → or SHIFT ←. ← The last display of a routine is indicated by the ← To return to other displays in the routine, press the → key or SHIFT ← to move 16 characters, one full display at a time. ↑ Indicates that the SHIFT key was pressed. NOTE: At any point in the sequence, a sub-menu may be exited by pressing SHIFT/ENTER. The [WAIT-CALCULATING] message is displayed briefly after the user changes displayed data on some of the screens and then exits the screen. 3-4 ACCESSING MODE DISPLAYS Ensure that all MODE displays are functional and that all options ordered from the factory are present by following the flow diagram in Figure 3-4, page 3-6. To follow the logic flow chart, use the following steps: NOTE: For more detailed instructions, refer to Figure 3-5 through Figure 3-8, Figure 3-11, and Figure 3-13 through Figure 3-15. 1. Press MODE. 2. Use the → key to move to the desired sub-menu (SECURITY, RANGE, DIAGNOSTICS, LINEARIZER, ALARM, CUR-RENT OUTPUT, AUTO-CAL or REMOTE I/O) and press ENTER. Rosemount Analytical Inc. A Division of Emerson Process Management 3. Press SHIFT then → to move through each sub-menu. 4. At the end of each routine, press SHIFT/ENTER to return to the RUN mode. 5. Repeat steps 1 through 4 to check the next function. 3-5 SECURITY CODE See Figure 3-5, page 3-7. The Model 880A is equipped with a security code feature, which is deactivated when the instrument is shipped from the factory. When the security feature is activated, only the STATUS and MODE function keys are active to access the STATUS and SECURITY displays. A valid password must be entered to activate the rest of the keyboard. INITIAL PASSWORD IS “880” This password may be changed to any three character group. Entering the correct password activates the keyboard. To gain access, follow the steps in the appropriate figure in this section. Once access has been gained, the procedure described in Figure 3-5, page 3-7, may be performed. In the event the password is misplaced, the operator may return to the initial password (880) through the following steps: 1. Press and release the RESET pushbutton switch on the Micro Board (see Figure 3-1, page 3-1). 2. Press and hold the ENTER key until the RUN mode display appears. Operation 3-5 Instruction Manual 748250-N June 2002 Model 880A RUN MODE MODE SECURITY RANGE DIAGNOSTICS LINEARIZER ALARM CURRENT OUT AUTO-CAL ENTER Will enter displayed mode function ENTER and ENTER will return analyzer to Run Mode Note: If Security is activated, display will return to Run Mode unless user enters Security Mode and enters password. REMOTE I/O Figure 3-4. Logic Flow Diagram 3-6 Operation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A A. ACCESSING SECURED SCREEN DISPLAYS. SECURITY ENTER PASSWORD: ??? ENTER RUN MODE Other screen displays now accessible. Two (2) minutes of keyboard inactivity restores secured status, requiring reentry of password. B. ACTIVATING/DE-ACTIVATING SECURITY FEATURES AND CHANGING PASSWORD. SECURITY ENTER PASSWORD: ??? SHIFT Toggles ON/OFF SECURITY: OFF “DATA STORED” ENTER SHIFT NEW PSWRD: ??? SHIFT RUN MODE Select three characters. Valid characters are “space”, 0 through 9 and A through Z. Note: ← → ENTER PSWRD IS NOW XXX SECURITY Activated SECURITY De-Activated If SECURITY is activated, follow procedure A above, first. and will move cursor right/left, one character at a time. SHIFT and and will return analyzer to RUN MODE. SHIFT and will go to next function. ENTER will change (toggle) settings. Figure 3-5. Security Mode Flow Diagram Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-7 Instruction Manual 748250-N June 2002 Model 880A cursor under the desired digit [NNN] and selecting a letter or number with ↑ or ↓ key. This name will appear on the display when the analyzer is in the run mode. 3-6 RANGE PARAMETERS a. Range Selection Reference Figure 3-6 below. There are several range parameters that may be changed. The first display [RANGE: # CMP NNN →] allows RANGE 1, RANGE 2 or RANGE 3 to be selected with the ↑ or ↓: key. Of these three independent ranges, RANGE 3 should always be the least sensitive range (highest fullscale range). b. c. Gain In the [GAIN=X] display, an amplifier gain of 1, 2, 4, or 8 can be selected for each range with the ↑ or ↓ key depending on the sensitivity desired (Refer to 5-5, page 5-2). Range 3 is normally the least sensitive range. Other ranges are generally set with gains that are proportional to their relative fullscale spans. Thus, if range 1 is 0 to 50 ppm CO and range 3 is 0 to 500 ppm CO, then the respective gains will usually be 8 and 1. Component of Interest The component of interest is designated by a 3-digit group of letters or numbers. This gas name or designation may be selected for each range by placing the RANGE SHIFT ENTER SHIFT SHIFT GAIN= X Digital Gain (X1, X2, X4, X8) Zero Gas Offset as a % of fullscale. ZR. OFFSET: 0.00 SHIFT SHIFT FS - XX ppm Cal Gas (Span) Concentration in ppm or %/Volume. CAL GAS = ppm RANGE=X CMP SO2 Fullscale Range in % or ppm TIME CONST = XX and will move cursor right/left, one character at a time. SHIFT and and will change (toggle) settings. SHIFT and Time Constant: 0.5 to 20 seconds will go to next function. ENTER will return analyzer to RUN MODE. Figure 3-6. Range Mode Flow Diagram 3-8 Operation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A NOTE: d. Range, Fullscale In the [FS=XXXX ppm *] or [FS=XX.X % *] display, up to a four-digit fullscale value is entered in ppm (parts per million). NOTE: The instrument will not allow the user to enter a value in the [CAL GAS = XXXX] screen that is larger than the fullscale value entered in the [FS = XXXX ppm) screen. e. Calibration Gas In the [CAL GAS=XXXX ppm *] display, up to a four-digit calibration gas value is entered in ppm for each linearized range. It is recommended that cal gas concentration be from 80% to 100% of fullscale. f. Zero Offset In the [ZR-OFFSET:X.XX *] display, the amount of zero offset in percent of fullscale is entered for each range. The zero offset feature compensates for impurities in zero calibration gas. If there are no impurities in the zero gas, set ZR-OFFSET to 0.00. g. Time Constant In the [TIME CONST=XX ← display, the value of the TIME CONSTANT can be changed for each range. This TIME CONSTANT is responsible for the amount of time (in seconds) in which the analyzer responds to change. A different TIME CONSTANT can be selected for each range. To change or check the settings of the different range parameters, follow the steps in the appropriate figure in this section. Rosemount Analytical Inc. A Division of Emerson Process Management After changing a setting, press ENTER to retain the new setting in nonvolatile memory. Settings stored in nonvolatile memory will be saved even in the event of a power outage. At any point in the sequence, the routine may be exited by pressing SHIFT/ENTER. The analyzer must be in LOCAL mode (L1, L2 or L3 appears in RUN MODE display) to change ranges in [RANGE=XXX] screen of Figure 3-6, page 3-8. 3-7 ANALYZER DIAGNOSTICS Diagnostics are selectable through the MODE function. This function allows the source current, detector signals, oscillator tune voltage, and the four power supply values (+5 V, +15 V, +12 V, and -15 V) to be displayed. It is recommended that the values for oscillator tune, detector signal and source current be recorded when the diagnostic display is first accessed. See Figure 3-7, page 3-11. 3-8 ZERO CALIBRATION The Model 880A Analyzer automatically calculates zero when the analyzer is in the zero setpoint mode. Simply press ZERO (display notes [ZERO - WAIT] and then [ZR = XX PS = XX %]). (Ensure that zero gas is flowing through the cell until display reading stabilizes.) Then press ENTER (display notes [CALCULATING ZERO]). Zero is then set for all three ranges, and the analyzer returns to Run Mode (after a delay of about 20 to 30 seconds). NOTE: When entering this function, ensure that zero calibration gas is flowing through the analyzer. When entering this function for viewing purposes only, press SHIFT/ENTER to exit without changing zero value. Operation 3-9 Instruction Manual 748250-N June 2002 Model 880A To calibrate zero: of function (after a delay of about 15 to 20 seconds). 1. Allow system to warm up a minimum of two hours. 2. Connect zero gas to the sample cell inlet at the back of the analyzer. Flow the gas at a flow rate of 500 cc/min, as read on a flowmeter, until display reading stabilizes. To calibrate the zero setting for the analyzer for all three ranges, press ZERO and then press ENTER. 3-9 SPAN CALIBRATION The Model 880A Analyzer sets span for the selected range in a simple two-keystroke procedure. To span the analyzer, the operator simply presses SPAN and ENTER. When SPAN is pressed, display notes [SPAN - WAIT] and then [X.XX NN % MMM → ], where X.XX is the run mode value, NN % is the percentage of span potentiometer in use and MMM is the span gas value. When ENTER is pressed, display notes [CALCULATING SPAN] and the analyzer re-enters Run mode on completion 3-10 Operation NOTE: For instruments with the Calibration Gas Control or Auto Zero/Span, press ENTER to perform the new calibration. Press SHIFT/ENTER to abort this function, turn off the relay for this valve, and maintain previous calibration settings. When entering this function, ensure that span calibration gas is connected to the analyzer. When entering this function for viewing purposes only (by pressing the SPAN key), press SHIFT/ENTER to exit. To perform span: 1. Allow system to warm up a minimum of two hours. 2. Connect span gas to the sample cell inlet at the back of the analyzer. Flow the gas at a rate of 500 to 1000 cc/min (1 to 2 SCFH), as read on a flowmeter, until the display reading stabilizes. 3. To calibrate, press SPAN and then ENTER. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A DIAGNOSTICS ENTER OSC. T = 75 to 80% of maximum. De-tuned in counterclockwise direction. SHIFT SHIFT DET. SIG. - X.XX 0.4V to 1.2V with zero gas flowing (see Sections 5-6 and 5-7) 1.2V to 7.5V with span gas (see Section 5-4) 7.5V max. On highest range. Adjust R3 on Signal Board (see Figure 3-1). +15V = XX.X SHIFT SHIFT SRC.CUR.=XXXmA Must be between 700mA and 950mA 700mA to 800mA for % to high ppm ranges 800mA to 950mA for mid to low ppm. Adjust R9 on Power Supply Board (See Figure 3-1). Refer to Data Sheet for initial factory setting. +12V = XX.X ±5% SHIFT SHIFT +5V = X.X ±5% -15V = XX.X ±5% and SHIFT and ±5% will move cursor right/left, one character at a time. ENTER will return analyzer to RUN MODE Figure 3-7. Diagnostic Mode Flow Diagram Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-11 Instruction Manual 748250-N June 2002 Model 880A Where X is the nonlinear input; A0, A1, A2, A3 and A4 are the linearization coefficients; and Y is the linear output. 3-10 LINEARIZATION The Model 880A Analyzer can be operated in the linear and non-linear mode. Linearization can be toggled ON/OFF with the ↑ or ↓ key in the Linearization Mode Screen (see Figure 3-8 below) In the OFF position, linearization is disabled for all ranges. In the linear mode, the component of interest is measured in engineering units, either ppm (parts per million) or % (percent of composition). In the non-linear mode, the component of interest is measured is in %FS (percent of fullscale). Linearization coefficients can be developed for each range and stored in the analyzer using the front panel keypad. The operating range is selected by entering RANGE = 1, 2, or 3 in the Range Mode. Coefficients for the selected range are automatically used, independent of the position of Range = n, from the Linearization Mode (except for the ALL Range selection). The analyzer is linearized with the following fourth-order polynomial: 2 3 4 Y = A0 + A1X + A2X + A3X + A4X LINEARIZER ENTER LIN: ON RANGE: X Press and linearizer ON/OFF. to toggle TO PREVIEW VALUES: Press ENTER to preview values for A1, A2, A3, A4 WITHOUT CHANGING THOSE VALUES. SHIFT TO CHANGE VALUES: will move cursor right AO = X.XXXXXXX and ENTER SHIFT will change (toggle) values of each character (Blank space after “=“ indicates the sign of the coefficient). will move to next coefficient. and ENTER SHIFT will return analyzer to RUN MODE. AO = _X.XXXXXXX SHIFT AO = X.XXXXXXX Figure 3-8. Linearizer Mode Flow Diagram 3-12 Operation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A a. All Range The “All” range is a special feature that allows the user to use Range 3 coefficients for all three ranges. It should only be used over dynamic ranges of 3:1 or less. If Range A is selected in the Linearization Mode, the microprocessor will use the coefficients in Range 3. Also, if the linearizer is ON and in Range A, the microprocessor will use the GAIN and TIME CONSTANT from Range 3, regardless of the GAIN and TIME CONSTANT selected for Ranges 1 and 2. b. Non-Standard Ranges and Coefficients When ordered, special linearization coefficients for non-standard fullscale ranges are entered in the appropriate range(s) at the factory. If one set of linearization coefficients has been ordered and a range has not been specified, these coefficients will be for Range 3. The user may want the display to read in engineering units (ppm). This response is linear over the operating range. The following coefficients will make no correction to the straight line response, but will cause the analyzer to display engineering units: A0 = 0.00000 A1 = 1.00000 A2 = 0.00000 A3 = 0.00000 A4 = 0.00000 To calculate linearization coefficients other than those installed at the factory, either 11 or 21 data points should be taken. (If urgent, a curve can be created with as few as 4 points. This should be considered temporary and a more accurate curve made with more points should be created as soon as possible.) Rosemount Analytical Inc. A Division of Emerson Process Management These data points can be obtained with an accurate gas divider or other flow mixing device. Before calculating coefficients, the data must be normalized to ranges of 0 to 1 units for both % and concentration readings. Then the axis must be reversed as illustrated in Figures 3-9 and 3-10. A multiple linear regression is then used to calculate coefficients. (For example: If the range is 0 to 5000 ppm and readings are 0 to 100%, then divide all of the concentrations by 5000 and the readings by 100. Put the normalized concentrations on the Y-axis and the normalized readings on the X-axis. These data points can be entered into any program capable of computing a fourth order polynomial curve. This curve will be the mirror image of the curve on the application sheet at the back of the manual, however the linearization coefficients will be different. Use the coefficients calculated with the curve for linearization coefficients. Use these coefficients to solve the following equation: 2 3 4 Y = A0 + A1X + A2X + A3X + A4X . After taking the data points, the user may determine coefficients for user-specific gas by either using any program capable of calculating a fourth order curve fit or calling the factory to have the specific coefficients calculated. When entering user-determined coefficients, note that the microprocessor only recognizes five significant figures to the right of the decimal point (i.e., 0.12345). Also, the user should ignore the three non-significant digits as they may change value while the significant digits are being changed. The values of the non-significant digits do not affect the instrument's linearity. Operation 3-13 Instruction Manual 748250-N June 2002 Model 880A 100 % READING % FULLSCALE 50 % 0 % 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 CONCENTRATION ppm Display ppm Figure 3-9. Typical Application Linearization Curve, Linearizer OFF 1 0.9 0.8 0.7 CONCENTRATION, NORMALIZED 0.6 0.5 0.4 0.3 0.2 0.1 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 READINGS, NORMALIZED (Axis Reversed) Figure 3-10. User Determined Linearization Curve (Normalized) 3-14 Operation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A condition (exceeding the alarm setpoint), the latch associated with the alarm is set. When the alarm condition clears, (run mode value is less than the alarm setpoint plus the deadband) the latch is reset. 3-11 ALARM The Alarm consists of two single point, field-programmable high or low outputs with a deadband of up to 20% of fullscale. The two alarm setpoints are programmable for one range selected, and are dimensionless. The alarms can be set with one alarm HIGH and one alarm LOW, both alarms HIGH or both alarms LOW. This option is completely user configurable (See Figure 3-11 below). The high alarm is determined when RUN mode value exceeds the alarm setpoint. The alarm is cleared when run mode value is less than alarm setpoint minus the deadband. The low alarm is determined when the run mode value is less than the alarm setpoint. This alarm is cleared when the run mode value is greater than the alarm setpoint plus the deadband. The Status Display (see Section 3-11a, page 3-16) will reflect an alarm condition should one occur. When the instrument is in alarm ALARM ENTER NOT INSTALLED ALARM: X MAN OFF Toggle between X = 1 or 2, and between MAN (manual) and AUTO (automatic) SHIFT RANGE: X Select Range 1, 2, or 3 for the alarm. Alarm only valid for selected range. Selecting a range disables alarm for other two ranges. SHIFT HIGH SET: XXXX Toggle between high set and low set, and adjust value. SHIFT DEADBAND: XX % and will move cursor right/left, one character at a time. and will change (toggle) settings SHIFT and will go to next function SHIFT and ENTER * * DATA STORED * * ENTER will return analyzer to RUN MODE RUN MODE Figure 3-11. Alarm Mode Flow Diagram Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-15 Instruction Manual 748250-N June 2002 ALARM 1 and ALARM 2 can be toggled with the up and down arrows to either AT (automatic) or MAN (manual). In the AUTO (automatic) setting, an alarm relay will be activated should an alarm condition occur. Alarms are calculated in the AUTO mode on the basis of parameter settings. The MANUAL mode is the test mode and alarms are not scanned by the CPU. In the MANUAL (test) mode, the ALARM ON/OFF can be toggled with the up and down arrows to set and reset the alarm latch. The Fail-Safe not only sets the alarm when an alarm condition is present, but also in the event of a power outage. Model 880A a. STATUS Display Refer to Figure 3-12 below. The STATUS display shows the alarms, error messages and security lockout status. (See explanations of error messages in Section 5-1, page 5-1) The STATUS display can be used to check the following alarm setpoints without entering one of the MODE functions: HIGH/LOW, AUTO/MANUAL and ON/OFF. The order of priority for error messages, security status and alarms is as follows: [SECURITY ENABLED/DISABLED] [ERL ] [EL-LIN.COEFF ERR] [E0-ZERO POT LMTS] [E1-SPAN #1 LMTS] [E2-SPAN #2 LMTS] [E3-SPAN #3 LMTS] [E4-ADC SATURATED] [E5-ZERO DRIFT] [E6-SPAN DRIFT] [E7-GAIN TOO HIGH] [RMT: R/L] [ALARM 1 AUTO/{MAN ON/OFF}] [ALARM 2 AUTO/{MAN ON/OFF}] [MAN-CAL PRESENT] [AUTOCAL: ON/OFF] [CURRENT 0/4 SP ON/OFF] Alarm 1 (15 sec.) {Followed by] Alarm 2 (15 sec.) Alarm ON or OFF ALARM 1 MN OFF Alarm: MN (Manual) or AT (Automatic) Figure 3-12. Status Display 3-16 Operation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A This function can represent any suppressed range with at least a 25% span. For example. a valid range could be 0% to 25%, 28% to 61% or 33% to 100%. When the Zero Span Suppression is off (NO), the analyzer defaults to the 0% to 100% range. 3-12 CURRENT OUTPUT Refer to Figure 3-13 below. The Model 880A Analyzer has a standard 0 to 20 or 4 to 20 mA current output with zero span suppression. CURRENT: X 20mA ENTER Toggle ZR/SPN SUPR: YES and Toggle keys to select between 0 to 20 mA and 4 to 20 mA. and keys to select YES or NO. SHIFT XX TO XXX FS Note: Current Output is factory set at 4 to 20 mA. If an adjustment is needed, Zero (R2, labeled OFFSET on the board) and Span (R1) potentiometers are located on the Current Output Board (Figure 2-6). SHIFT and ENTER will return analyzer to RUN MODE. Figure 3-13. Current Output Mode Flow Diagram 3-13 ZERO/SPAN CALIBRATION WITH CALIBRATION GAS CONTROL The Calibration Gas Control allows one-man calibration. This option consists of two form C contacts, rated 3A-125/250 VAC or 5A-30 VDC (resistive). These contacts are connected to solenoid valves (customer supplied) which will turn zero and span calibration gases on and off when activated. Simply press ZERO or SPAN to open the appropriate valve, thus allowing the gas to flow through the instrument. Press ENTER to initiate the calibration process. At the conclusion of calibration, the valve is closed and the instrument returns to Run Mode. See Section 3-16 (page 3-23) for more information. Rosemount Analytical Inc. A Division of Emerson Process Management NOTE: For instruments with Calibration Gas Control or Auto Zero/Span, press ENTER to perform the selected calibration. Press SHIFT/ ENTER to abort the function, turn off the relay for this valve, and maintain previous calibration settings. NOTE: When entering this function for viewing purposes only (by pressing the ZERO or SPAN key), press SHIFT/ENTER to exit. To calibrate the analyzer with the Calibration Gas Control. Operation 3-17 Instruction Manual 748250-N June 2002 1. Allow system to warm up a minimum of two hours. calibrated at each interval regardless of range(s) selected. 2. Connect the solenoid valve for the zero gas to the two form C contacts. Connect the zero gas to the sample cell inlet located on the back of the analyzer. The gas should flow at a rate of 500 cc/min, as read on a flowmeter, until the display reading stabilizes. The initial delay [DELAY nnn HR] display allows the user to select the amount of time until the first automatic calibration occurs. This is the initial delay until the automatic cycle starts. At this time a zero and span calibration is made regardless of selection. If a zero delay is selected there will be an automatic two minute delay. 3. To calibrate the zero setting for the analyzer, press ZERO. To calibrate the span setting for the analyzer, press SPAN. Wait for the reading to stabilize, and then press ENTER. 3-14 AUTO ZERO/SPAN Refer to Figure 3-14, page 3-20. The Auto Zero/Span allows automatic, unattended calibration at set intervals. The option has six contact closures, four of which are field programmable for frequency and duration of the calibration cycle (span 1, span 2, span 3 and zero). Meanwhile, the other two contact closures indicate insufficient zero and span adjustments and also drift limits for zero and span, if activated. The auto zero/span [AUTO-CAL: ON] display allows the user to select ON or OFF to turn the Auto Zero/Span “on” or “off”. Toggling from OFF to ON resets the timers for the Auto Zero/Span. To reset the timers when the Auto Zero/Span is “on”, toggle from ON to OFF to ON. The sample and hold [SH: YES] display allows the user to select YES or NO to turn the automatic sample and hold “on” or “off”. When the sample and hold feature is “on”, the recorder and Current Output do not get updated until the calibration sequence is completed. The range selection [RANGE: 1Y 2Y 3Y] display allows the user to select the ranges which will be automatically calibrated with span gas by using the →arrow to move the cursor to the desired range and using the ↑ or ↓ key to select Y (yes) or N (no) for each range. The zero for all three ranges will be 3-18 Model 880A Operation The purge [PURGE: nnn MIN] display allows the user to select the amount of time for the calibration gas to flow through the analyzer before the calibration starts for zero and span or the amount of time for sample gas to flow through the analyzer before run mode values are recorded when the sample and hold feature is selected. The analyzer is calibrated during the final minute of purge time. During the remaining purge time the signal is modified according to previous calibration data. The repeat zero [RPT ZERO nnn HR] display allows the user to select the amount of time between zero calibrations. This is the amount of time after the initial calibration before the zero calibration is repeated without repeating the span calibration. NOTE: Each time an auto span calibration is made, a zero calibration is also made regardless of selection. The keyboard is disabled during the auto zero/span sequence. During the auto zero/span sequence, the time constant is set to one second. Upon completion of the calibration sequence, the time constant is reset to the value chosen in Range Parameters. In order to engage the Auto-Cal function with the Remote Range I/O, the Auto-Cal function must be disabled by toggling AUTO-CAL to OFF in the [AUTO-CAL:OFF] display. The repeat span [RPT SPAN nnn HR] display allows the user to select the amount of time Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A between span calibrations. This is the amount of time after the initial span calibration before this calibration is repeated. The [DRIFT LIMIT: ON] display allows the user to determine the maximum amount of span and zero drift allowable. The [ZR-DFT: ± XX%] or [SP-DFT ± XX%] display allows the user to select the percentage of fullscale by which the analyzer is allowed to drift from the reference span or zero calibration values. The maximum zero drift limit is 10% fullscale and the maximum span drift is 15% fullscale. zero drift limit desired on the bottom scale and find the corresponding Recorder Deflection value on the side scale. These are the values that should be entered in [ZR-DFT: ± XX% → ←] or [S-DFT:R# ± XX% ←]. Calibration drift calculations for all ranges toggled "ON" in the [Range: 1Y 2Y 3Y] display include only calibrations occurring after initiation of the Calibration Drift function. Two reference zero and/or span calibrations after initiation of the Calibration Drift function are required for calculation of the Calibration Drift value. In the linearized mode, these values should be obtained from the Response Curve for Range located at the back of the manual. For the linear mode, locate the amount of span or Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-19 Instruction Manual 748250-N June 2002 Model 880A AUTO-CAL ENTER AUTO-CAL: OFF Toggle between ON and OFF to activate Auto Zero/Span feature. Toggling from OFF to ON resets the timers. RPT ZERO: nnn HR ENTER SH-V:N Select the number of hours between zero calibrations. (Zero cal occurs each time span cal does; therefore, this value is for zero cal alone.) ENTER SH-I:N Toggle between ON or YES (Y) and OFF or NO (N) for sample and hold features for voltage (V) and current (I). RPT SPAN: nnn HR ENTER Select the number of hours (1 ... 99) between each span calibration. (Zero cal occurs automatically before each span cal.) ENTER RANGE 1Y 2Y 3Y Toggle between YES (Y) and NO (N) for each range. DRIFT LIMIT: OFF ENTER Toggle drift limit feature ON/OFF. ENTER Select the number of hours (0 ... 99) until initial calibration. DELAY nn HR ZR-DFT: +/- 10% ENTER Select the % fullscale of zero drift (1 ... 50) allowable for all three ranges. ENTER PURGE: nn MIN Select the number of minutes (2 ... 99) duration of purge with sample or calibration gas. S-DFT:R1 +/- 15% Choose range (R1, R2, or R3) and corresponding percent fullscale of span drift (1 ... 50) allowable for each range. User may use to return to previous screen display, if desired. Press ENTER with cursor under changed value to store in nonvolatile memory. ENTER and will move cursor right/left, one character at a time. and will change (toggle) settings. SHIFT SHIFT and will go to next function. SHIFT SHIFT and ENTER ENTER will return analyzer to RUN MODE Figure 3-14. Auto Zero/Span Flow Diagram 3-20 Operation Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A When SPECIAL is selected, only autocal status and remote/local status on pins 8 and 9, respectively, are active. 3-15 REMOTE RANGE INPUT/OUTPUT Refer to Figure 3-15 below. The Model 880A Analyzer has optional remote range change and ID capability. When the Remote Range Input/Output is switched to REMOTE in the RUN mode, the range indicator at the right corner of the display will be R# instead of L#. Refer to Table 3-1 (page 3-22) and Table 3-2 (page 3-22) for explanations of BIN (binary) and DEC (decimal). This option allows the user to remotely change ranges and initiate Auto/Zero/Span. The input section is level triggered by the user's 5 to 24 VDC pulses. The output section allows monitoring ranges, auto-cal, and remote/local status. REMOTE I/O ENTER CNTRL: REMOTE Toggle between local and remote control. ENTER IN/OUT: BIN/BIN Select: BIN/BIN (Binary/Binary) DEC/BIN (Decimal/Binary) BIN/DEC (Binary/Decimal) SPECIAL* DEC/DEC (Decimal/Decimal). *SPECIALS are not recommended for general purpose use and are made custom; consult factory. and will move cursor right/left, one character at a time. and will change (toggle) settings. SHIFT and will go to next function. SHIFT and ENTER will return analyzer to RUN MODE Figure 3-15. Remote Input/Output Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-21 Instruction Manual 748250-N June 2002 Model 880A OUTPUT J2 PIN # INPUT DESIGNATION J3 PIN # DESIGNATION 1 Common 1 Range selection in remote 2 Range I.D. 2 Range selection in remote 3 Range I.D. 3 Range selection in remote 4 Not Used 4 Not Used 5 Not Used 5 Not Used 6 Not Used 6 Not Used 7 Not Used 7 Auto-Cal request 8 AUTO-CAL status 8 Not Used 9 REMOTE/LOCAL status 9 Common Note: The Auto-Cal request input is level triggered, therefore, it is the responsibility of the user to verify that the input is brought low before the analyzer completes the Auto-Cal process. Table 3-1. MODE BIN BIN BIN DEC DEC DEC RANGE R3 R2 R1 R3 R2 R1 Remote Range I/O Designation J3 PIN 3 0 0 0 1 0 0 J3 PIN 2 1 1 0 0 1 0 J3 PIN 1 1 0 1 0 0 1 1 = High Voltage Pulse (5 to 24 VDC) 0 = Low Table 3-2. 3-22 Operation Remote Range I/O Binary and Decimal Coding Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A 3-16 ROUTINE OPERATION First set the range for desired operating range: 1, 2, or 3. Then follow the steps for zero and span (Section 3-8 on page 3-9 and Section 3-9 on page 3-10). Next supply sample gas through the instrument. The Model 880A will now automatically and continuously analyze the sample stream. As a check of instrument performance, it is recommended that the operator keep a log of the zero/span status (percentage of pot value). 3-17 RECOMMENDED CALIBRATION FREQUENCY Maximum permissible interval between calibrations depends on the analytical Rosemount Analytical Inc. A Division of Emerson Process Management accuracy required and cannot, therefore, be specified. It is recommended initially that the instrument be calibrated once every 24 hours and that this practice be continued unless experience indicates that some other interval is more appropriate. Readout accuracy is directly proportional to change in barometric pressure (i.e., a change in cell pressure of 10 mm of mercury will result in a readout error of approximately 1% of reading). Therefore, if barometric pressure changes significantly, it is advisable to recheck the calibration against an upscale standard gas. 3-18 SHUTDOWN The Model 880A will retain settings during prolonged shutdown. Recalibrate the instrument upon restart. Operation 3-23 Instruction Manual 748250-N June 2002 3-24 Operation Model 880A Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A SECTION 4 THEORY 4-1 DETECTION SYSTEM THEORY As shown in Figure 1-1 on page 1-1, infrared radiation is produced from two separate energy sources. This radiation is interrupted by a chopper at 5 Hz. Depending on the application, the radiation may then be optically filtered to reduce background interference from other infrared-absorbing components. Each infrared beam passes through a cell, one containing a continuously flowing sample and the other cell sealed or with a continuously flowing reference gas. Rosemount Analytical Inc. A Division of Emerson Process Management During analysis, a portion of the infrared radiation is absorbed by the component of interest in the sample, with the quantity of infrared radiation absorbed being proportional to the component concentration. The detector is a “gas microphone” based on the Luft principle. It converts the difference in energy between sample and reference cells to a capacitance change. This capacitance change, proportional to component concentration, is processed and indicated on the display. Theory 4-1 748250-N June 2002 4-2 Theory Model 880A Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A SECTION 5 TROUBLESHOOTING 5-1 ERROR CODE SUMMARY NOTE: In the Run Mode, the error codes described in Table 5-1 below, may appear on the display. These messages also are shown on the STATUS display in a slightly different format. Error messages in are listed in order of priority. If several error conditions are active simultaneously, only one error message will take precedence in the Run Mode display. To view all error messages, press the STATUS key. NOTE: The ERL error message takes precedence over other error messages [ER0 ER7] in the Run Mode screen. RUN MODE DISPLAY STATUS DISPLAY Either an improper linearization coefficient or a CAL GAS value larger than fullscale has been inputted. See Section 5-10 on page 5-6 for further information. Zero Potentiometer setting is such that more than –500 mV is required to make a software zero. The zero pot cannot compensate. System must be balanced with source balance shutter adjustment. See Section 5-6 on page 5-3. ERL [EL-LIN.COEFF ERR] ERO [EO-ZERO POT LMTS] ER1 [E1-SPAN #1 LMTS] ER2 [E2-SPAN #2 LMTS] ER3 [E3-SPAN #3 LMTS] ER4 [E4-ADC SATURATED] ER5 [E5-ZERO DRIFT] ER6 [E6-SPAN DRIFT] ER7 [E7-GAIN TOO HIGH] [IR SOURCE ERROR] EXPLANATION Span errors for Range 1, Range 2, or Range 3. Software span is outside limits so that the rum mode value is not between 51% and 100% of the span gas value while in the Span Mode. Check gain settings. Signal into ADC is greater than fullscale rating. Refer to Figure 3-6 on page 3-8, and reduce the digital GAIN setting by one value, i.e. 8 to 4, 4 to 2 or 2 to 1. Zero drift limit exceeded. To clear, recalibrate or toggle the drift limit OFF and then ON. See Figure 3-14 on page 3-20. Span drift limit exceeded. To clear, recalibrate or toggle the drift limit OFF and then ON. See Figure 3-14 on page 3-20. The gain setting in the “RANGE” sub-menu is producing too high of a signal. Reduce gain. Infrared source current has been below 300 mADC for more than 2 minutes. Check source current, adjust R9 for minimum 700 mADC. Replace source, if required. Note: If any of the above error messages occur during calibration, software will restore previous calibration values. The analyzer is then operable under values resident before modification. Table 5-1. Rosemount Analytical Inc. Error Code Summary A Division of Emerson Process Management Troubleshooting 5-1 748250-N June 2002 Model 880A 5-2 VOLTAGE CHECKS Refer to Section 3-7 on page 3-9 and ensure that the voltages for the detector signal and the three power supplies are correct. application curve at the back of the manual. Multiply this value by 7.5 and record the resultant value for Step 5. For example, if the SPAN gas is 67 % of fullscale, then 5-3 OSCILLATOR TUNE ADJUSTMENT (0.67)(7.5)= 5 This procedure should not be performed on a routine basis: 1. Refer to Section 3-7 on page 3-9, and access the Oscillator Tune display. 2. Refer to Figure 1-1 on page 1-1. Adjust coil knob (Oscillator Tune, located on top of the detector housing) until a maximum reading is obtained on the display. In this case, the value to be used in Step 5 is 5. 3. Refer to Figure 1-1 on page 1-1. Adjust the displayed value with preamplifier gain potentiometer R3, located on the Signal Board, for the value obtained in Step 4. THIS VALUE SHOULD NEVER BE HIGHER THAN 7.5. NOTE: 3. Adjust the coil counterclockwise until the unit reads between 75 and 80% of the maximum value. 5-4 PREAMP GAIN The preamp gain is used to adjust the fullscale value at TP2 and the diagnostic display to 7.5V. To prevent saturation, this value must never be higher than 7.5V, fullscale. If this value is too low or is above 7.5V, adjust the preamp gain. 1. Refer to Section 3-7 on page 3-9, and access the Detector Signal display. 2. Flow SPAN calibration gas for the least sensitive range through the SAMPLE CELL until display reading stabilizes. An example: Range 1 - 500 ppm CO Range 2 - 2000 ppm CO Range 3 - 5000 ppm CO In this case, the least sensitive range would be 5000 ppm. If the calibration gas is not equal to fullscale, find the percent fullscale of the calibration gas by looking at the 5-2 Troubleshooting For applications with very low concentrations (for example Range 3 = 400 ppm CO), the fullscale value at TP2 and the Diagnostics Display may be considerably less than 7.5V. 5-5 DIGITAL GAIN ADJUSTMENT The digitally controlled GAIN amplifier does not normally need adjustment, however, in the event that the analyzer cannot be spanned, the GAIN must be adjusted as follows: Follow the STEPS for Spanning the Analyzer in Sections 3-9 on page 3-10 (standard analyzer) or 3-13 on page 3-17 (analyzer with the Calibration Gas Control Option) and span the analyzer. If the Run Mode value is not between 51% and 100% of the span gas value, while keeping the span potentiometer between 5% and 95%, then the digital GAIN should be adjusted. (The ideal span pot setting is 50%.) Note the final value of the PS (potentiometer status) for Step 4. 1. Exit to the Run Mode. 2. Follow the steps in Figure 3-6, on page 3-8, to obtain the GAIN display in the RANGE parameters menu. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A 3. Change the GAIN setting to a value higher or lower than the original value. The GAIN may be changed to 1, 2, 4, or 8. If the span potentiometer status (PS) was at the top of its range in Step 2 (95%), then the GAIN should be raised. If the span potentiometer status (PS) was at the bottom of its range in Step 2 (5%), the GAIN should be lowered. 4. Press SHIFT/ENTER to return to the Run Mode. 5. Repeat Step 1. If the analyzer still cannot be spanned, repeat steps 2 through 5 for a new GAIN value. 5-6 SOURCE BALANCE SHUTTER ADJUSTMENT 2. Flow zero gas (nitrogen) through the SAMPLE CELL until the display reading stabilizes. 3. Refer to Figure 1-1 on page 1-1. Slightly loosen the locking nut on the sample cell shutter adjust screw. The shutter adjust screw is located on top of the motor source assembly. 4. Using a screwdriver, rotate the shutter adjust screw until a minimum reading on the display is obtained. A typical reading is 0.2 to 0.5. Add 0.4 to this value. Use this value for Step 5. (If this reading exceeds 1.2 V, then a Source Alignment is necessary; see Section 57 on page 5-6.) 5. Rotate the shutter adjust screw clockwise (viewed from the screw head) until the display reads the value obtained in Step 4. NOTE: These adjustments are part of the factory checkout and are not normally required for routine operation, but must be performed whenever the optical system is disturbed (i.e., removal of cells for cleaning). 6. Re-tighten the locking nut. Ensure that the display does not change. 1. Access Diagnostics Mode (See Section 3-7 on page 3-9), and access the Detector Signal display. Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 5-3 748250-N June 2002 Model 880A Information Signal (5 Hz capacitance change) SOURCE Detector (Modulator) OSCILLATOR AMPLITUDE-MODULATED 10 MHz CARRIER HALFWAVE RECTIFIED CARRIER VOLTAGE DOUBLER OSCILLATOR BOARD SIGNAL BOARD AMPLIFIED UNFILTERED 5 HZ SIGNAL 5 Hz BANDPASS FILTER 5 Hz WITH NOISE FILTERED OUT FULLWAVE RECTIFIER FULLWAVE RECTIFIED 5 Hz SIGNAL BUFFER AMPLIFIER TIME CONSTANT LOWPASS FILTER ZERO SUPPRESSION SOFTWARE SPAN DIGITAL GAIN X1 X2 X4 X8 MUX ADC MICRO LIN ZERO DIGITALLY CONTROLLED DAC REF SPAN 1, 2, 3 DIGITALLY CONTROLLED DAC SOFTWARE ZERO Figure 5-1. Functional Block Diagrams 5-4 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A A. Functional Diagram - Circuitry in Tune Mode Tank Circuit Voltage Doubler Rectifier Detector Oscillator Tune Output Diaphragm Undistended DETECTOR Stationary Reference Metal Button Chamber L1 10 MHz Oscillator Sample Chamber Diaphragm at maximum Distention OSC. TUNE B. Tank Circuit Resonance Curves Curve 1. OSCILLATOR TUNE Control set for maximum obtainable meter reading. Curve 2. OSCILLATOR TUNE Control set for .75% to 80% of maximum obtainable meter reading. Curve 3. Sample beam blocked, causing maximum distention of diaphragm. Carrier Amplitude Max. Obtainable Amplitude Tank Circuit Resonant Frequency 75% to 80% of max. Amplitude with Sample Beam Blocked Crystal Frequency (10 MHz) Note: Decrease in inductance and/or capacitance in tank circuit shifts resonance curve to right, decreasing carrier amplitude. Figure 5-2. Modulation System Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 5-5 748250-N June 2002 Model 880A until the value on the display is within ±10 of the value on the application data sheet. Clockwise adjustment of R9 will increase the value. Counterclockwise will decrease the value. 5-7 SOURCE ALIGNMENT NOTE: These adjustments are part of the factory checkout, are not normally required for routine operation, and should be done only if the detector signal obtained is greater than 1.2V. WARNING BURN HAZARD The source housing is very hot. Ensure adequate measures are taken to avoid touching this component during this procedure. Before doing this procedure, balance the source as outlined in Section 5-6 on page 5-3. Then do the following: 1. Connect a digital voltmeter between TP6 and TP2 on the signal board. 2. Refer to Figure 6-2 on page 6-5. Set the source adjustment screw so that ½” of screw threads are visible (about halfway screwed in). 3. Loosen the two screws holding each source in place. 4. Adjust both measurement and reference sources up or down to reach the minimum detector signal. 5-9 CASE HEATER TEMPERATURE CONTROL Refer to Figure 7-1 on page 7-2 and Figure 7-2 on page 7-3. Malfunction in this option can occur in three sections: Heater - Check with an ohmmeter for continuity. The heater resistance is approximately 113 ohms at 25°C. Temperature Sensor - This is an RTD and should have approximately 550 ohms at 25°C. Check with ohmmeter for continuity. Over Temperature Fuse - This is a thermal fuse that opens above 72°C. Check for continuity with an ohmmeter. If the above are functional, refer to Drawing 624073 for circuit diagram and troubleshoot board. 5-10 ERL ERROR MESSAGE The error message, ERL, indicates one of two events has occurred: • An improper linearization coefficient has been inputted, thereby causing a calculation loop error. This message is only displayed in the Run Mode, and since the calculation is generally executed in Range Mode or the linearizer setup screens, the user will not see the ERL message until the analyzer is returned to the Run Mode. • If the user enters a CAL GAS value that is larger than the fullscale value, the ERL message may be displayed. In such an instance, the software attempts to calculate a percent-of-fullscale value which is higher than fullscale. 5. Re-tighten source housing screws. 6. Do the Source Balance procedure in Section 5-6 on page 5-3. 5-8 SOURCE CURRENT ADJUSTMENT 1. Follow the steps in Figure 3-7 (on page 3-11) to access the Source Current display. 2. Refer to Figure 3-1 on page 3-1. Adjust the trim potentiometer (R9) located on the Power Supply Board to view the desired current on the digital display 5-6 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A NOTE: The ERL message occurs only in extreme cases, i.e., FS value = 5 ppm and CAL GAS = 5000 ppm. If the user inputs, for example, 50 ppm on a fullscale of 5 ppm, the ERL message will not appear. But when the user attempts to span the range with this value, the ER# [SPAN POT LMTS] error message will appear instead. To correct this condition, do the following: 1. The user should cross-reference the linearizer coefficients entered with those provided by the factory (or those the user has calculated). Re-enter them properly. Exit into the Run Mode, and the ERL message should disappear. 2. If the coefficients are correct, then check the fullscale/CAL GAS value Rosemount Analytical Inc. A Division of Emerson Process Management relationship in the Range setup screens. Correct this condition, exit the Range setup screen, and once the calculation has been automatically redone, the ERL message will disappear. NOTE: The linearization calculation loop normally takes from 2 to 3 seconds to perform its task. If either of the two events described above occur, though, causing a calculation loop error, "WAIT-CALCULATING" may be displayed for up to 20 seconds before it exits with the ERL error message. Also, when the ERL message is flashing in the Run Mode screen, if the STATUS key is pressed, the message [EL-LIN.COEFF ERR] will be displayed briefly. Troubleshooting 5-7 748250-N June 2002 5-8 Troubleshooting Model 880A Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A SECTION 6 ROUTINE SERVICING WARNING ELECTRICAL SHOCK HAZARD Troubleshooting in the field requires access to live parts which can cause death or serious injury. Refer servicing to qualified personnel. 6-1 CELL REMOVAL, CLEANING AND INSTALLATION a. Long Cell Configurations Refer to Figure 6-1A on page 6-3. 1. Slide chassis out. 2. Remove sample lines from the end cap assembly and the end cap/optical filter assembly. 3. If installed, remove the two motor/source assembly support brackets. 4. Remove the two screws holding the motor/source assembly to the optical bench plate. 5. Support the cells and gently move the motor/source assembly away from the detector. The cells and its o-rings will now be free. 6. Rinse the cell with acetone. If this does not remove all foreign matter, use a soft brush. Do not use any metallic object inside the cell because it will scratch the gold plating. Loss of gold plating may require cell replacement. 7. After all matter has been removed, rinse the cell with distilled water Rosemount Analytical Inc. A Division of Emerson Process Management and allow to air dry. Do not use towels. 8. Inspect the cell inside by holding it up to a bright light. If particles are seen, repeat Steps 6 and 7 as often as necessary. 9. After cleaning cells, examine o-rings at the end cap assembly and end cap/optical filter assembly and replace If damaged. 10. Remove any contaminants from optical filters with a lint free cloth soaked in acetone. Do not use alcohol or other solvents. Allow to air dry. 11. To install the cells, fit into position. Make sure that the o-rings seat properly. Move the motor/source assembly back into position. Make sure that the o-rings seat properly. 12. Replace the two screws which hold the motor/source assembly to the optical bench plate. Do not overtighten. 13. Replace the two Motor/Source Assembly support brackets. 14. Install the sample lines. 15. Check for leaks as instructed in Section 2-8 on page 2-4. Take corrective action if necessary. 16. Replace desiccant if required (see Section 6-2 on page 6-4). 17. Perform source balance and source alignment adjustments per Sections 5-6 on page 5-3 and Section 5-7 on page 5-6. Routine Servicing 6-1 748250-N June 2002 b. Model 880A Short Cell Configurations Refer to Figure 6-1B on page 6-3. 1. Slide chassis out. 2. Remove sample lines from the sample cell assembly. 3. Remove the two screws holding the motor/source assembly to the optical bench plate. 9. Remove any contaminants from windows with a lint free cloth soaked in acetone. Do not use alcohol or other solvents. Allow to air dry. 4. Remove the two screws holding the end cap/optical filter assembly and sample cell assembly to the detector. Gently move the motor/source assembly away from the detector. The sample cell assembly, end cap/optical filter assembly and o-rings will now be free. 10. To install the cells, replace the two retaining screws holding the end cap/optical filter assembly and sample cell assembly to the detector. Verify that the o-rings seat properly. Move the motor/source assembly back into position. Verify that the compression gaskets seat properly. 5. Rinse the cell with acetone. If this does not remove all foreign matter, use a soft brush. Do not use any metallic object inside the cell. 11. Replace the two screws which hold the motor/source assembly to the optical bench plate. Do not overtighten. 6. After all matter has been removed, rinse the cell with distilled water and allow to air dry. Do not use towels. 12. Install the sample lines. 7. Inspect the cell inside by holding it up to a bright light. If particles are seen, repeat Steps 5 and 6 as often as necessary. 8. After cleaning cell, examine o-rings between the detector and sample cell assembly, and between the 6-2 sample cell assembly and end cap/optical filters assembly, and the compression gaskets between the end cap/optical filters assembly and plate assembly, replace If damaged. Routine Servicing 13. Check for leaks as instructed in Section 2-8 on page 2-4. Take corrective action if necessary. 14. Replace desiccant if required (see Section 6-2 on page 6-4). 15. Perform source balance and source alignment adjustments per Sections 5-6 on page 5-3 and 5-7 on page 5-6. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A A. LONG CELLS Sample In Desiccant Holders Sample Out End Cap/Optical Filter Assembly Motor/Source Assembly to Optical Bench Plate mounting screws End Cap Assembly Detector Assembly (See Figure 6-3) Motor/Source Assembly (See Figure 6-2) O-Rings Support Brackets (Shown in phantom for Detector Cover removed for clarity Cells Oscillator Tune Adjust Optical Bench Pl Detector Cover Motor/Source Assembly to Optical Bench Plate mounting screws Sample In/Out (interchangeable) B. SHORT CELLS Motor/Source Assembly (See Figure 6-2) Desiccant Holder Detector Assembly (See Figure 6-3) End Cap/Filter Assembly, Sample Cell to Detector i Plate Assembly O-Rings Detector Cover removed for clarity Compression Gaskets Oscillator Tune Adjust End Cap/Optical Filters Assembly O-Rings Cell Assembly Detector Cover Optical Bench Pl Figure 6-1. Optical Bench Cell Replacement Rosemount Analytical Inc. A Division of Emerson Process Management Routine Servicing 6-3 748250-N June 2002 Model 880A GAS CO2 CO H2O SOS CH4 Hexane CO + CO2 DESICCANT Cardoxide Mg (CI04)2 Mg (CI04)2 Mg (CI04)2 Mg (CI04)2 Mg (CI04)2 Cardoxide + Mg (CI04)2 Table 6-1. 6-2 CELL DESICCANT The reference cell may use a flowing reference. If so, desiccant is required. A desiccant holder is used on the inlet and outlets to keep moisture from entering the reference cell (see Figure 6-1 on page 6-3). The desiccant should be replaced each time the cell is opened. To determine the type of desiccant used, refer to Table 6-1above. Before inserting desiccant, purge cell with dry inert gas (i.e., N2). 6-3 SOURCE REPLACEMENT Refer to Figure 6-2 on page 6-5. Sources are marked with the resistance value, for example, 11.5 - 11.6 in matched pairs. Install the higher value as the reference source. NOTE: Observe how the parts are disassembled so that the reverse procedure can be used for reassembly. 1. Loosen the two screws on the front of the case and slide the front panel forward. 2. Remove the two screws holding the source housing to the chopper housing. 3. Remove the two screws holding the source to the source housing. Note how the source is mounted. There is a front and back side. 6-4 Routine Servicing PART NUMBER 096218 096217 096217 096217 096217 096217 096217/096218 Types of Desiccant 4. If replacing the source, insure that its orientation is exactly the same as the old one. Each source is marked on the back. Install the source with the higher designation at the reference site. 5. Reverse the procedure outlined above to reinstall the new source assembly, ensuring teflon spacers are in place and the screws have not been overtightened. Sources are ceramic and can crack or break under excessive pressure. 6-4 SOURCE BALANCE SHUTTER ADJUSTMENT When the sources are replaced, follow the Source Balance Procedure in Section 5-6 on page 5-3 to adjust the source balance shutter. 6-5 CHOPPER MOTOR ASSEMBLY To remove the chopper motor assembly, do the following : a. Long Cell Configurations 1. Refer to Figure 6-1A on page 6-3. Remove the two screws holding the motor/source assembly (with the end cap assembly attached) to the optical bench base plate. Support the cells and gently slide the motor/source assembly away from the cells. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A 2. Remove the two screws holding the end cap assembly to the motor/source assembly. optical bench base plate. Gently slide the motor/source assembly away from the cells. 2. Remove the two screws holding the plate assembly to the motor/source assembly. 3. Refer to Figure 6-2 below. Remove chopper cover. 4. Remove chopper blade. 3. Refer to Figure 6-2 below. Remove chopper cover. 5. Remove two screws from rear of motor and remove motor. 4. Remove chopper blade. b. Short Cell Configurations 1. Refer to Figure 6-1B on page 6-3. Remove the two screws holding the motor/source assembly (with the plate assembly attached) to the 5. Remove two screws from rear of motor and remove motor. Source Housing 622706 Source (Matched Pair) 624442 Chopper Motor 652605 Shutter Adjustment Screw 901351 O-Ring 900406 Jam Nut 801682 Screw 901753 Teflon Spacers Washer, Nylon 901077 Chopper Housing 624166 (Sapphire Windows) 624411 (Irtran Windows) Chopper Blade 620300 Chopper Cover 624167 Figure 6-2. Motor/Source Assembly Rosemount Analytical Inc. A Division of Emerson Process Management Routine Servicing 6-5 748250-N June 2002 Model 880A 2. Remove sample lines from the end cap assembly and end cap/optical filter assembly. 6-6 MICRO BOARD REPLACEMENT 3. Remove detector cover. All calibration constants and settings stored in non-volatile memory must be changed when the Micro Board is replaced. These procedures are given in Error! Reference source not found.. 4. While supporting the cells, remove the four screws holding the detector assembly to the optical bench base plate.. The detector assembly, detector heater, detector plate, cells and o-rings are now free Additionally, the ZERO potentiometer and the three SPAN potentiometers must be resynchronized with software. To resynchronize the ZERO potentiometer follow the steps listed below: 5. Disconnect ribbon cables. 6. Remove oscillator board. 1. Follow the instructions in Section 3-8, on page 3-9, for standard analyzer or Section 3-13, on page 3-17, for analyzer with Calibration Gas Control option and access the [ZR=X.X PS=XX%] display. Refer to Figure 6-3C on page 6-8. 7. Remove the two screws holding the end cap/optical filter assembly to the detector assembly. The end cap/optical filter assembly and orings are now free. 2. Press SHIFT then ↓. 3. Proceed with the ZERO calibration. 8. Remove the two screws holding detector to detector base. 4. The SPAN potentiometer must be resynchronized for all three ranges as follows: 5. Choose the first range by selecting a range using the range parameters in Figure 3-6 on page 3-8. 9. Detector, detector pad and detector base are now free. b. Removal - Short Cell Configurations Refer to Figure 6-3B on page 6-8. 6. Follow the instructions in Section 3-9, on page 3-10, for standard analyzer or Section 3-13, on page 3-17, for analyzer with Auto ZERO/SPAN option and access the [ X.XX XX % 100 ] display. 7. Press SHIFT then ↓. Proceed with the SPAN calibration. 6-7 DETECTOR REPLACEMENT a. Removal - Long Cell Configurations Refer to Figure 6-3A on page 6-8. 1. Slide chassis out. 6-6 Routine Servicing 1. Slide chassis out. 2. Remove the sample lines from the sample cell. 3. Remove detector cover. 4. Remove the four screws holding the detector assembly to the optical bench base plate. The detector assembly (with cell and end cap/optical filter assembly attached), detector heater, detector plate and o-rings (between end cap/optical filter assembly and plate assembly) are free. 5. Disconnect ribbon cables. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A 6. Remove oscillator board. Refer to Figure 6-3C on page 6-8. 7. Remove the two screws holding the end cap/filter assembly and cell to the detector assembly. The cell, end cap/optical filter assembly and o-rings are now free. 8. Remove the two screws holding detector to detector base. 9. Detector, detector pad and detector base are now free. Rosemount Analytical Inc. A Division of Emerson Process Management c. Detector Installation Replace detector by reversing the removal process. NOTE: When replacing detector, insure that the thermal fuse and temperature sensor mounted in the base plate are in good thermal contact with the base plate. Adjust source balance shutter and align source (see Sections 5-6 on page 5-3 and 5-7 on page 5-6). Routine Servicing 6-7 748250-N June 2002 Model 880A A. LONG CELLS Desiccant Holder Detector Cover Sample Line Sample Line O-Rings End Cap Assembly Detector Assembly End Cap/Optical Filter Assembly O-Rings Detector Heater 620298 Detector Plate Optical Bench Plate B. SHORT CELLS Sample Lines Detector Cover End Cap/Optical Filters Assembly Compression Gaskets Desiccant Holder O-Rings O-Rings Cell Assembly Optical Bench Plate Detector C. DETECTOR ASSEMBLY Oscillator Board 623998 Detector Pad Thermal Fuse 898733 Temperature Sensor 622917 Pad Detector Base Pad Figure 6-3. Detector Replacement 6-8 Routine Servicing Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A so reading decreases to between 75 % and 80 % of the maximum obtainable value noted in Step 1, above. See Resonance Curve Number 2, Figure 5-2B on page 5-5. This curve has the same shape as that obtained in Step 1, immediately preceding, but is displaced to the right. 6-8 ELECTRONIC CIRCUITRY a. Oscillator Circuit Board and Associated Elements of Amplitude-Modulation Circuit In the Oscillator Circuit (Drawing 623995) the 10 MHz carrier wave is generated by a crystal-controlled radio-frequency oscillator using crystal Y1 and transistors Q1 and Q2. The modulation circuit is driven by the detector, the sensing element of the analyzer. Mechanical functioning of the detector is explained in Section 4. Considered electronically, the detector is a two-plate variable capacitor. The modulator is coupled inductively, through one winding of inductance T1, to the oscillator. Amplitude of the 10 MHz carrier thus varies with the 5 Hz modulation signal. b. Functioning of Modulation System in TUNE Mode Preparatory to oscillator tuning, access Oscillator Tune (OT=XX) in the Diagnostic Display (Figure 3-7 on page 3-11). In this mode the display indicates the rms value of the halfwave-rectified carrier. The tank circuit is now adjusted in the following two-step sequence: Tuning: Initially, the OSC TUNE adjustment is set somewhat counterclockwise from its correct setting. Then, it is rotated clockwise to move the slug into the core, thus increasing inductance and decreasing resonant frequency. The adjustment is set for maximum obtainable reading. At this setting, tank-circuit resonant frequency is the same as oscillator frequency (i.e., nominal 10 MHz). See Resonance Curve Number 1, Figure 5-2B on page 5-5. Detuning: By counterclockwise rotation of the OSC TUNE adjustment, the slug is partially withdrawn from the core, thus decreasing inductance and increasing resonant frequency. The adjustment is set Rosemount Analytical Inc. A Division of Emerson Process Management c. Functioning of Modulation System in Operating Mode Overall sensitivity of the analyzer system may now be checked by placing SPAN gas in the sample beam to simulate absorption of sample-beam energy and thus provide the maximum obtainable 5 Hz detector-output signal. During that portion of the chopping cycle, while the chopper is not blocking the sample and reference beams, the diaphragm distends away from the metal button, thus decreasing detector capacitance and shifting the tank-circuit resonance curve to the right. At the moment the diaphragm reaches maximum distention, the curve reaches the position of Curve 3, Figure 5-2B on page 5-5. The diaphragm now pulses cyclically, causing the resonance curve to move continuously back and forth within the limits defined by Curves 2 and 3 of Figure 5-2B on page 5-5. Carrier amplitude decreases as the curve moves to the right and increases as it moves to the left. Thus, the response characteristics of the system depend on the location of Curve 2. Position of this curve depends on the degree of tank-circuit detuning used. By detuning to 75% to 80% of the maximum obtainable carrier amplitude and operating on the portion of the curve thus obtained, maximum slope yields highest sensitivity and minimum curvature provides best linearity. Routine Servicing 6-9 748250-N June 2002 d. Model 880A The amplitude-modulated 10 MHz carrier from the detector/oscillator circuit is applied to the radio-frequency demodulator. This circuit is a voltage-doubler type rectifier utilizing diodes CR1, CR2, CR3, CR4 and capacitor C7. The circuit gives approximately double the output voltage of a conventional halfwave rectifier. This result is obtained by charging a capacitor during the normally wasted half-cycle, and then discharging it in series with the output voltage during the next half-cycle. e. circuit, a chopper motor driver circuit, a proportional temperature controller circuit and a DC to AC converter for backlight. Radio-Frequency Demodulator Signal Board (DWG 624085) The 5 Hz sinewave detector signal goes through an AC amplifier U1A and associated resistor. The output signal goes through bandpass filter network U2 and U4 to remove harmonics and distortion. The signal next goes through a precision signal rectifier U3 and Q1 and then through low pass filter U5. This output goes through an RC low pass filter R29, C13 and U7 and then to inverting buffer amplifier U8 with zero control U11. g. Adapter Board (DWG 624127) The adapter board which includes a circuit breaker is used for line power distribution. The adapter board also serves as an interface board for all the option boards and provides the recorder output on TB2. h. Micro Board (DWG 623782) The Micro Board is a self-contained circuit assembly which includes an advanced microprocessor and multiple I/O functions with a complete analog domain consisting of analog-to-digital converters and digital-to-analog converters. Multiple output registers allow the transmission of digital data to and from the board under program control. The circuit board can be used alone or in conjunction with I/O boards that satisfy special interfacing requirements such as the following: 1. Current output The signal goes through a range amplifier consisting of eight bit DAC U9 and the amplifier U10. 2. Bi-directional remote range change board 3. Dual alarm assembly The GAIN is digitally controlled via U15, U16 and U18 resulting in a selectable digital GAIN of X1, X2, X4 and X8. The span is controlled for the three ranges with SPAN 1 (U12), SPAN 2 (U13) and SPAN 3 (U14). The eight-channel multiplexer (U17) selects the input signals by commands applied to the switch driver and feeds the selected signal to pin two of J2. f. Power Supply Board (DWG 655137) The power supply board supplies the different voltages to the various boards. Additionally, the power supply board includes an adjustable source driver 6-10 Routine Servicing 4. Auto ZERO/SPAN 5. Calibration Gas Control The microprocessor is configured with various memory arrangements depending on the application: RAM, PROM, EEPROM. The 64K memory is available for all memory functions. A selective arrangement allows rotating memory on specific boundaries. The board is configured with an analog domain that allows the processing of analog signals directly with a 12-bit plus sign ADC. In addition, two independent DAC's, each 12 bytes wide, allow the presentation of analog voltages for peripheral functions immediately. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A i. one-man calibration. Provision is made to assign a specific address in the range 0 through 7 using jumpers. Case Heater Temperature Control Board (DWG 624003) This is a proportional temperature controller, which works on a variable time method. k. Resistors' R7, R8, R9, R10, R11 and the sensor form a bridge which feeds a comparator, AR1. AR1 operates in an ON/OFF mode to drive transistor Q3. The sensor is a resistor with a positive temperature coefficient (1.925 ohms/°C). The resistance is 500 ohms at 0°C. Resistors R1 through R6, Q1, Q2 and C1 provide the circuit for the time proportioning action; C1 charges until the voltage on C1 reaches 9.0 V. Q1 then discharges C1, and the charging process repeats itself. The emitter of Q2 follows the voltage on C1, which is essentially a sawtooth. This is injected into the bridge, which causes the setpoint to bump on a variable time basis. Q3 (Through LED CR1) triggers optical coupler U1 which gates TRIAC (U2). U2 allows fullwave VAC to flow through the case heater element. j. The remote range change board is a peripheral circuit function which communicates with the computer via an 8-bit buss arrangement. This assembly provides isolated two-way communication between the host instrument and external user devices. Provision is made to assign a specific address in the range 0 through 7 using jumpers. l. Rosemount Analytical Inc. A Division of Emerson Process Management Auto ZERO/SPAN Board (DWG 624599) The auto ZERO/SPAN board is a peripheral circuit function which communicates with the computer via an 8-bit bus. With the appropriate software it satisfies the auto ZERO/SPAN requirement. The assembly provides six form C relay contact outputs, four of which are suitable for medium power requirements, the remaining two are relegated to alarm or indicator functions. Snubbers are provided for the medium power relays. Provision is made to assign a specific address in the range 0 through 7 using jumpers. Dual Alarm/Calibration Gas Control Board (DWG 624204) This board is used for both dual alarm and calibration gas control, depending on the position of the jumper in the jumper-selectable address. This is a peripheral circuit function which communicates with the computer via an 8-bit buss arrangement. This option consists of two form C contacts rated 3A-125/250 VAC or 5A-30 VDC (resistive). This circuit board satisfies a dual alarm requirement, as it provides two medium power relays that can be independently controlled from the central processor. Also, the board can be used to connect user-supplied solenoid valves to zero and span calibration gases for Isolated Remote Input/Output Board (DWG 624251) m. Current Output Board (DWG 624092) This board changes the instrument voltage output to an isolated current output for use with external recorders or data gathering systems. n. Auto Range Change This option couples the Isolated Remote Input/Output Board and the Alarm Board into a single function. When the alarm setpoint is triggered, the remote I/O board will automatically change ranges according to preset configurations. Routine Servicing 6-11 748250-N June 2002 Model 880A Jumper Configuration Option Board Function Dual Alarm E1 + E2 E5-E7, E9-E10 Dual Alarm - Fail Safe E1 + E2 E6-E7, E8-E10 Calibration Gas Control E1 + E4 E5-E7, E9-E10 Auto Zero/Span E1 -------------------- Isolated Remote I/O E4 -------------------- Table 6-2. 6-12 Address Routine Servicing Jumper Configurations for Option Boards Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A SECTION 7 REPLACEMENT PARTS The following parts are recommended for routine maintenance and troubleshooting of the Model 815 Explosion-Proof NDIR Analyzer. If the troubleshooting procedures do not resolve the problem, contact Rosemount Analytical Customer Service Center (see page 8-1). number (8803-XX or 8804-XX) is on the Data Sheet in the rear of this manual. a. Reference Figure 7-1 on page 7-2. 654849 655135 898724 622700 622751 623785 624088 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 b. 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. The cost of test and replacement will exceed the cost of a rebuilt assembly. As standard policy, rebuilt boards are available on an exchange basis. Because of the exchange policy covering circuit boards the following list does not include individual electronic components. If circumstances necessitate replacement of an individual component, which can be identified by inspection or from the schematic diagrams, obtain the replacement component from a local source of supply. 7-2 SELECTED REPLACEMENT PARTS While the following sections list parts which are common to all Model 880A applications, the configuration number is required when ordering parts which are specific to an individual application. The configuration Rosemount Analytical Inc. A Division of Emerson Process Management Model 880A Common Parts LCD Display Power Supply Board Power Amplifier Resistor Assembly Transformer Micro Board Signal Board Case Heater Temperature Control Assembly (Option) Reference Figure 7-2 on page 7-3. 624006 622917 624433 622733 622732 c. Temperature Control Board Temperature Sensor Thermal Fuse Fan Heater Optical Bench Reference Figure 6-2 on page 6-5, Figure 6-3 on page 6-8, and Figure 7-3 on page 7-4. 623998 898733 622917 620298 652605 624442 Oscillator Board Detector Thermal Fuse Detector Temperature Sensor Detector Heater Chopper Motor Source (Matched Pair) Replacement Parts 7-1 748250-N June 2002 Model 880A Power Supply Board 655135 Transformer 622751 Power Amplifier 898724 Case Heater Temperature Control Option (See Figure 7-2) Resistor Assembly 622700 Optical Bench (See Figures 6-1 and 7-3) Note: Long Cell shown. LCD Display 654849 Micro Board 623785 Signal Board 624088 Sensor, Case Heater Temperature Control Option (See Figure 7-2) Figure 7-1. Model 880A Assembly 7-2 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A Temperature Control Board 624006 Sensor 622917 (See Figure 7-1 for mounting location) Thermal Fuse 624433 Fan Assembly 622733 Heater Assembly 622732 Figure 7-2. Case Heater Temperature Control Assembly Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 7-3 748250-N June 2002 Model 880A LONG CELLS Desiccant Holder O-Rings Desiccant Holder Motor/Source Assembly (See Figure 6-2) O-Rings O-Rings Detector Assembly (See Figure 6-3) O-Rings Cells End Cap/Optical Filters Assembly Detector Heater 620298 Optical Bench Pl Detector Plate SHORT CELLS O-Rings End Cap/Optical Filters Assembly Compression Gaskets Desiccant Holder Detector Assembly (See Figure 6-3) Motor/Source Assembly (See Figure 6-2) Plate Assembly O-Rings O-Rings Cell Detector Heater 620298 Optical Bench Plate Detector Plate 7-4 Replacement Parts Figure 7-3. Optical Bench Assembly Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748250-N June 2002 Model 880A SECTION 8 RETURN OF MATERIAL 8-1 RETURN OF MATERIAL If factory repair of defective equipment is required, proceed as follows: 1. 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 instructions or it will not be accepted. Rosemount CSC will provide the shipping address for your instrument. In no event will Rosemount be responsible for equipment returned without proper authorization and identification. 2. Carefully pack the defective unit in a sturdy box with sufficient shock absorbing material to ensure no additional damage occurs during shipping. 3. In a cover letter, describe completely: • The symptoms that determined the equipment is faulty. • The environment in which the equipment was operating (housing, weather, vibration, dust, etc.). • Site from where the equipment was removed. • Whether warranty or non-warranty service is expected. • Complete shipping instructions for the return of the equipment. 4. Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in the Rosemount Return Authorization, prepaid, to the address provided by Rosemount CSC. Rosemount Analytical Inc. Process Analytical Division Customer Service Center 1-800-433-6076 Rosemount Analytical Inc. A Division of Emerson Process Management If warranty service is expected, the defective unit will be carefully inspected and tested at the factory. If the failure was due to the conditions listed in the standard Rosemount warranty, the defective unit will be repaired or replaced at Rosemount’s option, and an operating unit will be returned to the customer in accordance with the 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. 8-2 CUSTOMER SERVICE 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 8-3 TRAINING A comprehensive Factory Training Program of operator and service classes is available. For a copy of the Current Operator and Service Training Schedule contact the Technical Services Department at: Rosemount Analytical Inc. Customer Service Center 1-800-433-6076 Return of Material 8-1 Instruction Manual 748250-N June 2002 8-2 Return of Material Model 880A Rosemount Analytical Inc. A Division of Emerson Process Management WARRANTY Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, part(s) and consumables are capable of being renewed, repaired or replaced. The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any other cause. All other warranties, expressed or implied are hereby excluded. IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER. Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond Seller's direct control. Instruction Manual 748250-N June 2002 Model 880A Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com Fisher-Rosemount GmbH & Co. Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209 ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd. 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65-777-8211 F 65-777-0947 EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd. Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354 http://www.processanalytic.com © Rosemount Analytical Inc. 2001 LATIN AMERICA Fisher - Rosemount Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882