Instruction/ maintenance manual of the product 700 XA Emerson
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System Reference Manual 2-3-9000-744, Rev G September 2014 700XA Gas Chromatograph Applies to the Rosemount ® Analytical 700XA Gas Chromatograph and the Danalyzer ™ 700XA Gas Chromatograph.
NOTICE ROSEMOUNT ANALYTICAL, INC. (“SELLER”) SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS IN THIS MANUAL OR OMISSIONS FROM THIS MANUAL. SELLER MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, I.
Warranty 1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise expressly provided herein, Rosemount Analytical, Inc.
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Contents Chapter 1 Introduction ...................................................................................................................1 1.1 Description of manual ............................................................................
3.3.3 Electrical and signal ground ......................................................................................... 34 3.3.4 Electrical conduit ..................................................................................................
4.4.18 Recommended spare parts ....................................................................................... 127 4.4.19 Upgrading the embedded software ...........................................................................127 Appendices and reference Appendix A Local operator interface .
Contents iv.
1 Introduction This section describes the contents and purpose of the 700XA Gas Chromatograph System Reference Manual , a description of the Model 700XA system, an explanation of the theory of operation, and a glossary of chromatograph terminology. Use this section to get acquainted with the basic engineering of the 700XA.
The GC-to-PC interface provides the user with the greatest capability, ease-of-use, and flexibility. MON2020 can be used to edit applications, monitor operations, calibrate streams, and display analysis chromatograms and reports, which can then be stored as files on the PC’s hard drive or printed from a printer connected to the PC.
In most cases it is essential to use MON2020 to configure and troubleshoot the GC. The PC may be remotely connected via ethernet, telephone, radio or satellite communications. Once installed and configured, the GC can operate independently for long periods of time.
1.4.2 MON2020 MON2020 is a Windows-based program that allows the user to maintain, operate, and troubleshoot a gas chromatograph. Individual GC functions that can be initiated or controlled by MON2020.
After the equipment/software has been installed and the operation stabilized, automatic operation can be initiated via an ethernet network. 1.5 Theory of operation The following sections discuss the theory of operation for the GC, the engineering principles and the concepts used.
In the quiescent condition, prior to injecting a sample, both legs of the bridge are exposed to pure carrier gas. In this condition, the bridge is balanced and the bridge output is electrically nulled. The analysis begins when the sample valve injects a fixed volume of sample into the column.
1.5.2 Flame ionization detector The other detector available for the 700XA is the flame ionization detector (FID). The FID requires a polarization voltage and its output is connected to the input to a high impedance amplifier that is called an electrometer.
LSIV cross section Figure 1-5: The LSIV penetrates the wall of the lower compartment and is held in place by a retaining ring. The mounting arrangement is designed to ensure integrity of the flameproof enclosure. The outermost end houses an air-operated piston.
1.5.5 Data acquisition Every second, exactly 50 equally spaced data samples are taken (i.e., one data sample every 20 milliseconds) for analysis by the controller assembly. As a part of the data acquisition process, groups of incoming data samples are averaged together before the result is stored for processing.
Onset is defined where the detector output exceeds the baseline constant, but peak termination is defined where the detector output is less than the same constant.
The response factor calculation, using the external standard, is: AR F n = Are a n Cal n or HR F n = H t n Cal n where ARF n area response factor for component “n” in area per mole percent Area n .
CON C n = Are a n AR F n or CON C n = H t n HR F n where ARF n Area response factor for component “n” in area per mole percent. Area n Area associated with component “n” in unknown sample. CONC n Concentration of component “n” in mole percent.
and can be configured to auto zero anytime during the analysis if the component is not eluting or the baseline is steady. The TCD is only auto zeroed at the start of a new analysis. Baseline Signal output when there is only carrier gas going across the detectors.
RxD, RD, or S in Receive data, or signal in. TCD Thermal conductivity detector. A detector that uses the thermal conductivity of the different gas components to produce an unbalanced signal across the bridge of the preamplifier. The higher the temperature, the lower the resistance on the detectors.
2 Equipment description and specifications Use the following sections to reference the 700XA equipment description or specifications. 2.1 Equipment description The 700XA consists of a copper-free aluminum explosion-proof chamber, and a front panel assembly.
The switch panel The switch panel contains a network of on/off switches that allow you to manually control the GC’s stream and analytical valves. 8-stream switch panel (left) and 18-stream switch panel (right) Figure 2-2: There are two types of switch panels: 8-stream and 18-stream.
• OFF - The valve turns off and remains off until the operational mode is changed. To set a valve to OFF mode, set its switch on the switch panel to the “center” position—that is, the switch is neither flipped “up” nor “down”. • ON - The valve turns on and remains on until the operational mode is changed.
Status LEDs (Bottom of switch panel) Figure 2-6: • CPU - Green light blinks continuously while the GC is running. • Valves - Turns green if the valves are functioning automatically; turns red if the valves’ automatic settings have been overridden.
• 8 infrared-activated touch screen keys that eliminate the requirement for a magnetic pen. • Complete GC status, control and diagnostics, including full chromatogram display. See Appendix A for more information about operating the LOI. 2.1.2 Upper compartment The upper compartment contains the following components: • Valves .
- Heater/Solenoid board The card cage also has four additional slots for the following optional PCBs: - A second preamp board - A second heater/solenoid board - Two optional communications boards WARNING! The explosion-proof housing should not be opened when the unit is exposed to an explosive environment.
The mechanical pressure regulators and gauges are used to set and monitor the pressure of the carrier gas flow through the GC's columns, as well as the pressure of the FID air and fuel (H 2 ). The regulators and gauges are located beneath the GC.
Type Specification Mounting • Floor mount • Pole mount: - 2” (60.3 mm) - 3” (89.0 mm) - 4” (114.3 mm) • Direct wall mount Power • 24V DC standard (21-30 V DC operating voltage range); MAX 150 watts • (optional) 100-120/240 V AC; 50-60 Hz Note Voltage range includes line voltage variations.
Type Specification Analog inputs 2 connectors on the backplane, isolated Standard analog outputs 6 connectors on the backplane, isolated Optional analog outputs 8 connectors on optional expansion boar.
Type Specification Firmware Embedded firmware. Can be upgrade with MON2020. Methods 4 Timed Event tables and 4 Component Data tables assignable to each stream. Peak Integration • Fixed time or auto slope and peak identification. • Update retention time upon calibration or during analysis.
Type Maximum Number of Re- cords Remarks Daily Averages (Up to 250**variables) 365 1 Year Weekly Averages (Up to 250** variables) 58 1 Year Monthly Averages (Up to 250** variables) 12 1 Year Variable .
Equipment description and specifications 26.
3 Installation and setup This section provides instructions for installing and commissioning the 700XA. Installing a 700XA involves the following steps: 1. Observing precautions and warnings. 2. Planning site location and mounting arrangement. 3. Obtaining supplies and tools.
WARNING! The unit is required to be used in a well ventilated area. WARNING! All gas connections must be properly leak tested at installation. WARNING! No user replaceable part inside except a few parts that are only allowed to be accessed by trained service personnel.
Note When the vapor regulators and flow switches are fitted they must be suitably certified with the ratings Ex d IIC Gb T5/T6/T4 and for a minimum ambient temperature range Ta = -20°C to +60°C .
3.2.1 Wall mount The simplest mounting arrangement is the wall mount. If ‘Wall Mount’ is specified on the sales order, the unit will be shipped with a wall mount installation kit. Four locations on the mounting ears are available for support. 1. The unit is most easily mounted if a pair of 7/16-inch dia.
2. Maneuver the GC so that the notches in the mounting ears can be placed over the bolts on the wall and then place the washers over the bolts. 3. Install the second pair of bolts with washers and then tighten all the bolts. 3.2.2 Pole mount The pole mount arrangement uses an additional plate and spacers to allow the necessary clearance for nuts.
7. Place the nuts with washers on the upper bolts and then tighten all bolts. WARNING! Until all bolts are tight, the unit should be supported to prevent unforeseen accidents. 8. Adjust the lower bracket to align the bolts with the plate. Tighten the bolts.
3.3 Gas chromatograph wiring 3.3.1 Power source wiring Follow these precautions when installing power source wiring: • All wiring, as well as circuit breaker or power disconnect switch locations, must conform to the CEC or NEC; all local, state, or other jurisdictions; and company standards and practices.
• All process signal wiring should be of a single, continuous length between field devices and the GC. If, however, the length of the conduit runs require that multiple wiring pulls be made, the individual conductors must be interconnected with suitable terminal blocks.
Interior ground lug, lower enclosure Figure 3-4: • Resistance between the copper-clad steel ground rod and the earth ground must not exceed 25 Ohms. • On ATEX-certified units, the external ground lug must be connected to the customer’s protective ground system via 9 AWG (6mm 2 ) ground wire.
• All conduit fitting-threads, including factory-cut threads, must be coated with a metal-bearing conducting grease prior to assembly. • Temporarily cap the ends of all conduit runs immediately after installation to prevent accumulation of water, dirt, or other contaminants.
Dryers and Filters Use small sizes to minimize time lag and prevent back diffusion. • Install a minimum of one filter to remove solid particles. Most applica- tions require fine-element filters upstream of the GC. The GC includes a 2-micron filter. • Do use ceramic or porous metallic type filters.
Note The serial number for MON2020 is located on the back of its CD-ROM case. 2. If your GC is configured with an FID, remove the vent plug from the FID outlet. The vent plug has a tag attached to it that reads “REMOVE VENT PLUGS PRIOR TO OPERATION”.
• 14 AWG (American Wire Gauge), 18 MWG (Metric Wire Gauge) or larger electrical wiring and conduit to provide 120 or 240 volts AC, single phase, 50 to 60 Hertz, from an appropriate circuit breaker and power disconnect switch. See guidelines in Section 3.
CAUTION! Check the unit prior to wiring to determine if it is equipped for DC power. Failure to observe this precaution may damage equipment. To connect a 24 VDC power source to the GC, do the following: 1. Locate the plug-together termination block inside the electronics enclosure.
Location of entries for wiring on the under side of the lower enclosure Figure 3-6: Use the following table for the DC power wiring details: Attribute Wire Color + (positive) red – (negative) black Note Do not disconnect the factory-installed ground wire.
1. Locate the plug-together termination block inside the electronics enclosure, atop the power supply and adjacent to the card cage. AC/DC termination block Figure 3-7: WARNING! Do not connect the AC power leads without first ensuring that AC power source is switched OFF.
1. Remove the plug from the 1/16-inch sample vent tubing marked “SV1” that is located on the flow panel assembly. Depending on your GC’s configuration, there may also be a second sample vent marked “SV2”.
• Use a dual-stage regulator with high-side capacity of 3000 psig and low-side capacity of 150 psig. • See Appendix B for a description of a dual-cylinder carrier gas manifold (P/N 3-5000-050) wit.
3.5.4 Maximum effective distance by communication protocol type The table below lists the maximum distance at which the indicated protocol can transmit data without losing effectiveness. If longer runs are required, the use of a repeater or other type of extender will be necessary to maintain the protocol's efficiency.
1. Start MON2020 and connect to the GC. 2. Select I/O Cards... from the Tools menu. The I/O Cards window displays. 3. Change the Card Type for the appropriate I/O slot to Communication Module - Modem . 4. Click Save . MON2020 displays the following message: The GC must be rebooted for the ROC Card changes to take effect 5.
6. Make sure that the Comm Address matches the Modbus Id from the Communication window. 7. Select the appropriate modem from the Modem drop-down list. The Edit Telephone Number dialog box displays. 8. Enter the modem’s telephone number and click OK .
Ethernet ports on the backplane Figure 3-10: 1. Plug one end of the Ethernet cable into the PC’s Ethernet port and the other end into the GC’s RJ45 socket on J22 on the backplane. 2. Locate the set of switches at SW1, directly beneath the Ethernet port on the back plane.
SW1 switches on the back plane Figure 3-11: Note Make sure the SW1 switch is set to off (1) before connecting the GC to your local network; else, the GC will disrupt the local network's functioning. 3. Wait for 20 seconds and then do the following to ensure that the server has provided an IP address to the PC: a.
7. To configure the PC to accept IP addresses issued from the GC, select the Obtain an IP address automatically and Obtain DNS server address automatically check boxes. 8. Click OK to save the changes and to close the Internet Protocol (TCP/IP) Properties window.
CPU board link lights Figure 3-12: 4. Do the following to ensure that your network adapter is enabled: a. Go to Start → Control Panel → Network Connections . b. Check the status of the Local Area Connection icon. If the status appears as Disabled , right-click on the icon and select Enable from the context menu.
J23 serial port on the backplane (A) Figure 3-13: To set up the PC for the direct connection, do the following: 1. Do the following to install the Daniel Direct Connect modem driver onto the PC: a. Navigate to Start → Control Panel and double-click the Phones and Modem Options icon.
c. Select the New GC text and type in a new name for the GC connection. Note You can enter optional but helpful information about the connection in the Short Desc column. d. Select the new GC’s Direct check box. e. Click the Direct button located at the bottom of the GC Directory window.
Note The GC can be connected (or remain connected) to the local network on TB11 on the back plane while the DHCP feature is being used. Wired Ethernet terminal block on the backplane Figure 3-15: Use the following schematics as a guide to wiring the GC via its Phoenix connector at TB11.
CAT5e wiring to TB11 Figure 3-17: Once you have wired the cable to the Ethernet terminal, plug the other end into a PC or a wall jack. See Section 3.5.12 to continue configuring the GC. 3.5.12 Assigning a static IP address to the GC To configure the GC with a static IP address, do the following: 1.
5. Log off the GC. 6. Access the backplane, which is located in the GC’s lower enclosure. Port locations on the backplane Figure 3-18: 7. If you are setting up a static IP address for the Ethernet port at J22, and you also intend to connect to your company’s local area network, do the following: a.
10. Select the new profile and click Ethernet... Enter the GC’s static IP address in the IP address field. 11. Click OK . The Ethernet Connection Properties for New GC window closes. 12. Click Save on the GC Directory window. 13. Click OK to close the GC Directory window.
Note The discrete digital input terminals are optically isolated from the GC's other circuitry. 2. Route digital I/O lines appropriately, especially in the case of the explosion-proof enclosure.
Typical field wiring of a ROC800 DI module Typical wiring Figure 3-20: Terminal Label Definition 1 1 CH 1 Positive 2 2 CH 2 Positive 3 3 CH 3 Positive 4 4 CH 4 Positive 5 5 CH 5 Positive 6 6 CH 6 Positive 7 7 CH 7 Positive 8 8 CH 8 Positive 9 COM Common 10 COM Common To connect the ROC800 DI module to a field device, do the following: 1.
Note Twisted-pair cables are recommended for I/O signal wiring. The module’s terminal blocks accept wire sizes between 12 and 22 AWG. A minimum of bare wire should be exposed to prevent short circuits. Allow some slack when making connections to prevent strain.
Discrete Digital Outputs (continued) Table 3-2: TB3 Function Pin 10 DIG_OUT NC4 Pin 11 DIG_OUT ARM4 Pin 12 DIG_OUT NO4 Pin 13 DIG_OUT NC5 Pin 14 DIG_OUT ARM5 Pin 15 DIG_OUT NO5 Note Form-C relays are .
Typical field wiring of a ROC800 DO module Typical wiring Figure 3-23: Terminal Label Definition 1 1+ Positive discrete output 2 COM Discrete output return 3 2+ Positive discrete output 4 COM Discrete.
2. Insert the exposed end into the clamp beneath the termination screw. 3. Tighten the screw. 3.5.14 Analog input wiring All 700XAs have at least two analog inputs. An additional four analog inputs are available with a ROC800 AI-16 card that can be installed into one of the optional slots in the card cage.
Factory settings for analog input switches Figure 3-25: Note To set an analog input to accept a voltage (0-10 VDC) source, flip the appropriate switch in the opposite direction from that shown in Figure 3-25 .
Typical wiring for line-powered transmitters Figure 3-26: Optional analog inputs When plugged into one of the optional card slots on the card cage, the ROC800 AI-16 card provides four additional analog inputs. The AI channels are scalable, but are typically used to measure either a 4-20 mA analog signal or a 1-5 V dc signal.
Typical field wiring of a ROC800 AI-16 module Typical wiring Figure 3-28: To connect the ROC800 AI-16 module to a device, do the following: CAUTION! Failure to exercise proper electrostatic discharge precautions—such as wearing a grounded wrist strap—may reset the processor or damage electronic components, resulting in interrupted operations.
Calibrating a ROC800 AI-16 module To calibrate the ROC800 AI-16 module you must have a PC with the ROCLINK 800 Configuration program installed and open. 1. Select the Configure → I/O → RTD Points → Calibration tab. 2. Select an Analog Input . 3.
TB4 on the black plane Figure 3-29: Analog Outputs Table 3-4: TB4 Function Pin 1 + Loop1 Pin 2 Loop_RTN1 Pin 3 + Loop 2 Pin 4 Loop_RTN2 Pin 5 + Loop 3 Pin 6 Loop_RTN3 Pin 7 + Loop 4 Pin 8 Loop_RTN4 Pi.
Wiring for six analog outputs Figure 3-30: Figure 3-31 shows the factory settings for the analog output switches that are located on the Base I/O board.
Wiring and switch settings for customer-powered analog outputs It is possible to furnish power to each analog output while maintaining isolation between channels.
Settings for analog output switches Figure 3-33: Optional analog outputs When plugged into one of the optional card slots on the card cage, the ROC800 AO card provides four additional analog outputs. Each channel provides a 4 to 20 mA current signal for controlling analog current loop devices.
Terminal Label Definition 6 COM Analog output return 7 4+ Positive analog output 8 COM Analog output return 9 N/A Not used 10 N/a Not used To connect the ROC800 AO module to a field device, do the following: 1. Expose the end of the wire to a maximum length of ¼ inch (6.
7. Repeat Step 5 again. If leaks persist, check the valve ports with a commercial gas leak detector. Do not use a liquid leak detector such as Snoop ® on the valves or components in the oven. 3.6.2 Purging carrier gas lines Purging carrier and calibration gas lines requires power and a PC connected to the GC.
8. Select Control → Auto Sequence . For more information about this function, refer to the MON2020 Software for Gas Chromatographs manual. Note A purging period of 4 to 8 hours (or overnight) is recommended, during which no changes should be made to the settings described in Step 1 through Step 7 .
4 Operation and maintenance 4.1 Warning and precautions WARNING! Observe all precautionary signs posted on the 700XA. Failure to do so can result in injury or death to personnel or cause damage to the equipment. CAUTION! Turn off GC before removing a card from the card cage assembly.
The GC is ready to analyze the sample or validation stream using the 2 Pt Exp and the Resp Factor that were calculated during the LCG and HCG runs. 4.3 Troubleshooting and repair concept The most effi.
Operation and maintenance 4 Operation and maintenance 77.
4.4.2 Routine maintenance procedures • To give yourself a basis for comparison in the future, complete the maintenance checklist at least two times each month. Place the sales order number, date, and time on the form and file it. • Save a chromatogram of the operating GC on the PC with MON2020.
Hardware alarms Use the following table to identify the alarm and possible cause and solution for the problem. Alarm Name Possible Causes/Solution LTLOI Failure No switch panel detected or connected. Recommended actions: 1. Power the GC down completely.
Alarm Name Possible Causes/Solution Low Battery Voltage A low battery voltage has been detected on the CPU board. Re- place the CPU board immediately to avoid losing GC configura- tion data. Recommended actions: 1. Save the GC Configuration to a PC. 2.
Alarm Name Possible Causes/Solution Stream Skipped One or more streams in the stream sequence cannot be analyzed because their “Usage” option is set to “Unused”. Recommended actions: Use MON2020 to do one of the following: Remove the unused stream(s) from the stream sequence.
Alarm Name Possible Causes/Solution Flame Over Temperature The FID flame temperature is above safe limits set at the factory and the FID flame has been extinguished, the fuel supply valve closed, and automatic analyses halted. Recommended actions: 1. Confirm that both fuel and air cylinders are connected and contain sufficient volume.
Alarm Name Possible Causes/Solution No sample flow 1 (Applies to the optional sample flow switch.) There is no sample flow in the GC. Recommended actions: Check sample gas rotometer in the sample conditioning system for flow and do one of the following: If no gas flow or no rotometer is present, do the following: 1.
Alarm Name Possible Causes/Solution Analog Input 1 Low Signal Analog Input 2 Low Signal Analog Input 3 Low Signal Analog Input 4 Low Signal Analog Input 5 Low Signal Analog Input 6 Low Signal Analog I.
Alarm Name Possible Causes/Solution Stream 1 Validation Failure Stream 2 Validation Failure Stream 3 Validation Failure Stream 4 Validation Failure Stream 5 Validation Failure Stream 6 Validation Fail.
Test points Lower enclosure showing test points on the back plane Figure 4-1: The backplane has a set of test points that allow you to measure the voltage output of the Base I/O card. Each test point is labeled with a voltage value that, when measured with a voltmeter, should give a measurement equal to what is displayed on the label.
Voltage LEDs Figure 4-2: The following LEDs are associated with the following GC components: LED GC Component FUSE OPEN Glows red when the fuse has blown or been removed; otherwise, it is not lit. 24 LOOP (Power) Glows green when the current loop for the analog outputs is functioning prop- erly; otherwise, it is not lit.
When viewing the Heater window, the typical heater configuration is as follows: • Heater 1 is the analytical block heater. • Heater 2 is the “high hat” heater. The Temperature column on the Heaters window displays the current temperature; the Current PWM column displays the percentage of power being used to run the heater.
The Detectors window Figure 4-3: Configure the following fields from the Detectors dialog: • FID Ignition - manual or automatic • Ignition Attempts • Wait Time Between Tries • Igniter ON durat.
Plugged lines, columns, and valves If the lines, columns, or valves are plugged, check the gas flow at valve ports. For a reference, use the flow diagram in the drawing package, and remember these points about flow diagrams: • Port-to-port flow paths are indicated by solid or dashed lines.
XA valves Figure 4-4: Valve overhaul Note Replacement factory-built XA valves are available. Call your Emerson Process Management representative for more information.
The torque bolt Figure 4-5: 8. Holding the lower piston plate, pull the valve straight off the block. The alignment pins may stick slightly. 9. Remove and discard the old valve diaphragms and gaskets. 10. Clean the sealing surface as required using a non-lint-forming cloth and isopropyl alcohol.
1. Remove the thermal cover from the upper enclosure. 2. Loosen the ultem thumb screw and tilt the oven on its side to gain access to the solenoids that are located on the underside of the ultem. 3. Loosen the screws holding the solenoid in place and remove the solenoid.
TCD with block Figure 4-6: Replacing a TCD Use the following procedure to remove a TCD assembly from the GC for repair or replacement: WARNING! Disconnect all electrical power to the unit and ensure the area is free of explosive gases. Failure to follow this warning may result in injury or death to personnel or cause damage to the equipment.
Components of a TCD block Figure 4-7: 4. To replace the TCD, reverse the steps taken to remove it. Note The block screws should be tightened with a torque wrench to 20 inch-ounce. 4.4.8 Removing the FID The FID has no replaceable parts. Damage such as a broken RTD or igniter coil will require that the unit be removed and replaced.
The FID Figure 4-8: Use the following procedure to remove an FID from the GC: 1. Disconnect all power to the unit. Allow at least 10 minutes for the components to cool-down. 2. Locate the FID switch, which is on the half-moon-shaped wire terminal board, and flip it to the "off" position.
The location of the FID switch Figure 4-9: 3. Remove the explosion proof dome and the thermal hood. 4. Remove the screw connecting the termination board to the FID cap. 5. Remove the two screws from the mounting bracket. 6. Unscrew and remove the vent connector.
MAT LSIV components Figure 4-10: Note For a detailed view of the MAT LSIV’s components, see Figure 4-14 . To install the MAT LSIV, do the following: 1. Install new MAT valve by doing the following: a. Attach the retaining ring from step 6c above to the MAT LSIV.
Required tools Although for the most part it is possible to remove or disassemble the LSIV with traditional tools such as a wrench or pliers, the following tools should have been delivered with your L.
CAUTION! This unit operates at high temperature. Allow a cool-down period of at least 10 minutes after shut-down and handle the unit carefully. Failure to follow this precaution may result in injury or death to personnel. MAT LSIV components Figure 4-12: Note For a detailed view of the MAT LSIV’s components, see Figure 4-14 .
700XA after LSIV (A) has been removed Figure 4-13: Replacing LSIV seals Due to the possible damage caused by the presence of solids in the sample stream, combined with the regular, repeated motion of the injection valve stem, LSIV seals may require annual replacement.
This will expose the sample flow chamber and the old seals that ride the metering rod (ID No. 25), which should be treated with great care to prevent bending or scratching. 3. Pull the sample flow chamber assembly (ID No. 13) off the metering rod. Remove the two seals (ID No.
LSIV - exploded view Figure 4-14: 4.4.10 Methanator maintenance The optional methanator, which is a catalytic converter, converts otherwise undetectable CO 2 and/or CO into methane by adding hydrogen and heat to the sample. The methanator requires little maintenance.
Note Be sure to insulate the methanator assembly to prevent heat loss. Methanator assembly Figure 4-15: The RTD is replaceable. When replacing it, take care to anchor the RTD cable to the tubing to prevent loosening over time. To replace the RTD, consult drawing #CE-22210, which is available at the back of this manual.
4.4.11 Measure vent flow You will need an accurate flow meter for this measurement. To measure the measure vent flow, do the following: Measure flow vents Figure 4-16: 1. Consult the documentation the Parameter List that was provided with the GC to learn the appropriate flow rate.
To access the card cage, do the following: 1. Ensure electrical power is disconnected from the unit and the environment is safe. 2. Unscrew and remove the front panel. Remove the front panel Figure 4-17: 3. Unscrew and remove the switch panel or LOI. Remove the switch panel or LOI Figure 4-18: The PCBs are located in the card cage.
PCBs in the card cage Figure 4-19: 4. Note the location and direction of any board removed. Release the catch(es) and remove/replace the circuit board(s) as necessary.
AC/DC power supply located in lower compartment Figure 4-20: A Cross point #2 Phillips screw driver is required to remove and replace the AC/DC power supply. To remove and replace an AC/DC power supply, do the following: 1. Remove power to the GC. 2. Unscrew and remove the front panel.
Remove the switch panel or LOI Figure 4-22: 4. If present, remove the clear cover from the card cage. The card cage Figure 4-23: 5. Unplug all the cards in the card cage but do not remove them. 6. Unscrew the three switch panel connector posts. Remove the washers as well.
12. Remove the nut just above the power supply. The power supply may now be twisted free of the attaching stud and lifted from its cradle. Remove the power supply carefully to avoid damage due to wire interferences. 13. Maneuver the new power supply into the cradle, ensuring that the wires are free to be connected.
Heater/Solenoid board factory jumper setting Figure 4-25: Base I/O board factory jumper and switch settings Figure 4-26: Backplane factory switch setting Figure 4-27: 4.4.14 Communications The 700XA has four serial communications ports: Port 0, Port 1, Port 2, and Port 3, which is a dedicated PC-to-GC port.
Name Location Connector Type ETHERNET1 J22 RJ45 (DHCP-enabled) ETHERNET2 TB11 4-wire terminal block Ethernet ports on the backplane Figure 4-28: Maximum distance by communication type Communication Ty.
Port Name Port Mode Terminal Block Location on the back plane Communication Modes Sup- ported Port 0 RS232 TB1 Modbus ASCII/RTU RS422, RS485 TB2 Port 1 RS232 TB5 Modbus ASCII/RTU RS422, RS485 TB6 Port.
RS-232 Figure 4-29: RS-422 (Full Duplex/4-Wire) Figure 4-30: RS-485 (Half Duplex/2-Wire) Figure 4-31: Therefore, if you want to set Port 1 to RS-232 mode, you would set channel “2” on SW13 to the down position.
Serial port switches on the Base I/O board Figure 4-32: 10. Make sure that SW12 is set to the down position or Port 0 will not function. Note Ordinarily SW12 should never be adjusted. It is used by the factory for testing purposes. If it was somehow set to the top, be sure to return it to its factory-set position, which is the down position.
RS-232 RS-422 (Full Duplex/4-Wire) RS-485 (Half Duplex/2-Wire) Port 0 Port 1 Port 2 14. Access the backplane and consult the following graphic to locate the appropriate terminal blocks: Operation and .
Terminal block locations on the backplane Figure 4-33: 15. Once the appropriate termination blocks are wired correctly, you can start up the GC. Optional RS-232 serial ports It is possible to install an optional RS-232 board in one or both of the expansion I/O slots provided on the GC’s card cage in the electronics enclosure.
5. Turn off the GC. 6. Install the RS-232 board into the appropriate I/O card slot in the GC’s card cage. 7. Start the GC. Optional RS-485/RS-422 serial ports It is possible to install an optional RS-485 board in one or both of the expansion I/O slots provided on the GC’s card cage in the electronics enclosure.
Termination IN Termination OUT J4 In Out J6 In Out TB1 Wire Terminals RS-485 (Half Duplex/2-Wire) RS-422 (Full Duplex/4-Wire) A RxTx+ Rx+ B RxTx- Rx- Y NC Tx+ Z NC Tx- 4.4.15 Installing or replacing a FOUNDATION fieldbus module The FOUNDATION fieldbus module Figure 4-34: The FOUNDATION fieldbus module should be mounted adjoining the card cage.
Removing a FOUNDATION fieldbus module Note Be sure to properly ground yourself before performing this procedure. To remove the module, do the following: 1. Unscrew the two LOI post tips. The FOUNDATION fieldbus module can now be detached from the card cage.
FOUNDATION fieldbus wiring on the backplane Figure 4-35: Connecting the GC’s FOUNDATION fieldbus module to a Fieldbus segment The FOUNDATION fieldbus module has a terminal at TB1 on the carrier board, which is the middle card in the stack. This terminal can be used to connect to a fieldbus segment.
Connecting the optional ground wire If you wish to provide the Foundation Fieldbus module with surge protection, there is a ground lug at TB2 on the module’s carrier board, which is the middle card in the stack. One end of the ground wire should be attached to this lug nut, and the other end should be attached to the frame of the GC.
Board Jumper Set? LOI J1 Yes For more details, consult the following drawings: Preamplifier board Figure 4-38: JP1 on the preamplifier board should not be set. The preamplifier board is located in slot 1 of the card cage. Heater/solenoid driver board Figure 4-39: JP1 on the heater/solenoid driver board should not be set.
The Base I/O board, which is located in slot 3 of the card cage, has three jumpers that affect the performance of the Foundation Fieldbus. JP1 on the Base I/O board Figure 4-40: JP1 on the Base I/O board should be set. JP2 on the Base I/O board Figure 4-41: JP2 on the Base I/O board should not be set.
JP3 on the Base I/O board Figure 4-42: JP3 on the Base I/O board has three pins, and the jumper should be set on pins 2 and 3. CPU board Figure 4-43: S3 and S4 on the CPU board should be switched to OFF , which is the left-most position while holding the board right-side up.
LOI board Figure 4-44: The J1 jumper is located on the back of the LOI, at the top while holding the LOI right-side up. It should be set. 4.4.16 Analog inputs and outputs The analog outputs can be calibrated or adjusted with MON2020.
4.4.18 Recommended spare parts See Appendix C for the lists of recommended spare parts. The quantities listed in the tables represent the number of spares to cover most contingencies for up to five GCs or for more than 5 GCs or critical installations.
Operation and maintenance 128.
Appendix A Local operator interface A.1 Interface components for displaying and entering data The local operator interface (LOI) has multiple components that you can use to interact with the unit.
The GC is currently running an analysis. The GC has at least one unacknowledged alarm. The GC has an out-of-tolerance or alarm condition that requires an operator action. A.1.2 LCD screen The LCD screen measures 111.4mm by 83.5 mm and is capable of 640 by 4800 VGA pixel resolution, supporting both text and full graphics.
Pressing a key A key is “pressed” by placing a finger on the glass over the associated key hole and then removing the finger. Holding a finger over the key hole will cause that key to repeat until the finger is removed. A.2 Using the local operator interface A.
Pressing F1 when “MOVE” is displayed in the green box below it takes the focus inside the screen so that you can navigate through the controls of the screen using the LEFT, RIGHT, UP and DOWN keys. Pressing EXIT returns the focus to the top level—that is, outside of the screen.
The F1 and F2 keys are context dependent. A one-word description of the function of each of these keys displays in a green prompt box directly under the key in the title bar of the top-level full-sized screen. In some cases, F1 acts as a toggle between scrolling either a line or a page at a time.
When you press a key, a green square will flash in the upper left corner if the key is valid; if the key is not valid, a red box will flash in the upper left corder. A.2.4 Editing numeric fields When the focus is on an editable field, pressing F1 (EDIT) will display the Edit Dialog containing the field’s original text.
The EXIT key cancels any changes that were entered and closes the Edit Dialog, restoring the previous value to the field. A.2.5 Editing non-numeric fields The function of the keys when editing non-numeric data is context-dependant. Editing alphanumeric fields Alphanumeric fields take numbers (0 - 9) and letters (a - z, A - Z).
Selecting an item from a list box 1. Press F1 (SELECT) while focused on the list box to switch it to edit mode. Selecting a list box Figure A-3: 2. Use the UP and DOWN arrows keys to move between the values within the list box.
Selecting a combo box Figure A-4: 2. Use the UP and DOWN arrow keys to move between the selections. 3. Press ENTER to select the desired value or press EXIT to restore the combo box’s initial value. Entering a date and time 1. Press F1 (SELECT) while focused on the Date and Time field and the Enter the Date and Time dialog displays.
Entering a date and time Figure A-5: 2. Use the UP and DOWN arrow keys to change the value of the unit—that is, to go from January to February, or from 1 to 2. 3. Use the LEFT and RIGHT arrow keys to change units—that is, to go from months to years or hours to minutes.
A.3 Screen navigation and interaction tutorial This tutorial, which guides you through the procedure for editing data on a screen, will incorporate all of the preceding information to demonstrate the typical method of navigating and interacting with the LOI.
Note Notice that the green prompt boxes are empty. This means that the F1 and F2 keys are inactive from the Main Menu . 2. Click ENTER. The System screen displays. The System screen Figure A-7: Note Notice the navigation icon in the upper right corner, which indicates that no arrow keys are active.
You must log in to the GC before editing a screen Figure A-8: Note Notice that there is also a navigation icon on the Login dialog. 7. Click F1 (SELECT) and navigate up or down the list to highlight your user name.
The Enter the data dialog allows you to edit the selected field Figure A-9: 12. To delete a character, press F1 (BACKSP). To enter new data, use the UP and DOWN arrows to cycle through the available characters, and use the RIGHT arrow key to add a new character to the field.
Note If a validation error is found after pressing ENTER, an “Invalid Entry” message displays. Press ENTER to close the message and then re-enter your data. 14. Use the down arrow to move to the Is Multi User Write Enabled? check box. The Is Multi User Write Enabled? check box Figure A-11: 15.
The Is Multi User Write Enabled? check box, no longer checked Figure A-12: 16. Click F1 (SELECT) again to re-select the check box. 17. Navigate to the GC Mode field. The GC Mode field Figure A-13: 18. Press F1 (SELECT). The Select an Item combo box displays.
The Select an Item combo box Figure A-14: 19. Use the DOWN arrow to scroll down to the last item in the combo box. Press ENTER. 20. Press ENTER a second time to save all the changes that were made to the table. Note If you neglect to press ENTER at this point, all of your changes will be lost.
Submenu Command Subcommands Reference Live Chromatogram Screen (Ad- vanced Mode) Figure A-18 Archived Chromatogram Screen (Advanced Mode) Figure A-19 Live & Archived Chromatogram Viewer Options Me.
Submenu Command Subcommands Reference Logs/Reports Maintenance Log Figure A-46 Event Log Figure A-47 Alarm Log Figure A-48 Unack Alarms Figure A-49 Active Alarms Figure A-50 Report Display Figure A-51.
The Chromatogram menu Figure A-15: The Chromatogram Settings screen Figure A-16:.
The Live Chromatogram View (Status Mode) screen Figure A-17: Note The blue box displays the current analysis time. The Live Chromatogram View (Advanced Mode) screen Figure A-18:.
Note The blue box displays the current analysis time. The Archived Chromatogram (Advanced Mode) screen Figure A-19: The Live & Archived Chromatogram Viewer Options screen Figure A-20:.
Note The blue box displays the cursor’s x- (analysis time) and y- (amplitude) coordinates. The CGM Scaling screen Figure A-21: The Chromatogram CDT Table screen Figure A-22:.
The Chromatogram TEV Table screen Figure A-23: The Chromatogram Raw Data Table screen Figure A-24: A.4.2 The Hardware menu The Hardware menu enables you to view and manage the GC’s hardware components.
Refer to the “Using the hardware functions” section of the MON2020 Software for Gas Chromatographs User Manual for detailed information regarding the Hardware menu screens.
The Valves screen Figure A-27: Note The usage (Sample/BF1, Dual Column), mode (Auto, Off), and state (green = on, black = off, red = error) of each valve is displayed. See the “Configuring the valves” section of the MON2020 Software for Gas Chromatographs User Manual for more information.
The Detectors screen Figure A-29: The Discrete Inputs screen Figure A-30:.
The Discrete Outputs screen Figure A-31: The Analog Inputs screen Figure A-32:.
The Analog Outputs screen Figure A-33: The Installed Hardware screen Figure A-34: A.4.3 The Application menu The Application menu allows you to view the CDT, TEV and streams tables for the GC. The System , Status , and Ethernet Ports screens are also accessible from this menu.
Refer to the “Using the application functions” section of the MON2020 Software for Gas Chromatographs User Manual for detailed information regarding the Application menu screens.
The CDT screen Figure A-37: The TEV - Valve Events screen Figure A-38:.
The TEV - Integration Events screen Figure A-39: The TEV - Spectrum Gain Events screen Figure A-40:.
The TEV - Analysis Time screen Figure A-41: The Streams screen Figure A-42:.
The Status screen Figure A-43: The Ethernet Ports screen Figure A-44: A.4.4 The Logs/Reports menu The Logs/Reports menu enables you to view the various reports that are available from the GC.
Refer to the “Logs/Reports” section of the MON2020 Software for Gas Chromatographs User Manual for detailed information regarding the Logs/Reports menu screens.
The Event Log screen Figure A-47: The Alarm Log screen Figure A-48:.
The Unack Alarms screen Figure A-49: The Active Alarms screen Figure A-50:.
The Report Display screen Figure A-51: A.4.5 The Control menu The Control menu enables you to stop, calibrate, or place on automatic control a sample stream from the analyzer. Refer to the “Control menu” section of the MON2020 Software for Gas Chromatographs User Manual for detailed information regarding the Control menu screens.
The Control menu Figure A-52: The Auto Sequence screen Figure A-53:.
The Single Stream screen Figure A-54: The Halt screen Figure A-55:.
The Calibration screen Figure A-56: The Validation screen Figure A-57:.
The Stop Now screen Figure A-58: A.4.6 The Manage menu The Manage menu enables you to change the LOI’s settings, change a user’s password, and log off of the GC to which you are connected. Refer to the “Manage menu” section of the MON2020 Software for Gas Chromatographs User Manual for detailed information regarding the Manage menu screens.
The Manage menu Figure A-59: The LOI Settings screen Figure A-60:.
The Create PIN screen Figure A-61: The Diagnostic screen Figure A-62: A.5 Troubleshooting a blank LOI screen If the LOI is powered up but the LCD screen is blank, do the following: 1.
2. Flip the LOI over to expose its motherboard and associated electronics. Jumpers at J105 on LOI motherboard Figure A-63: 3. Check the jumpers located at J105 on the motherboard. These jumpers control the screen’s power. To function properly, jumper pins 3 and 4 must be set; if they are not, set them.
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Appendix B Carrier gas installation and maintenance B.1 Carrier gas This appendix provides a description of the optional carrier manifold (P/N 3-5000-050) that permits the connection of two carrier gas bottles, or cylinders, to a gas chromatograph (GC) system.
V-1 Carrier cylinder 1 Bleed valve V-2 Carrier cylinder 1 Block valve V-3 Carrier cylinder 2 Block valve V-4 Carrier cylinder 2 Bleed valve B.2 Installation and line purging To install and purge the dual-bottle carrier gas manifold, proceed as follows: 1.
B.3 Replacing carrier cylinder To replace one carrier cylinder without interrupting GC operation, proceed as follows: 1. Turn cylinder valve off. 2. Back off on cylinder pressure regulator until handle turns freely. 3. Remove cylinder. 4. Attach new cylinder to regulator and repeat Steps 3 through 7 of Section B.
Carrier gas installation and maintenance 178.
Appendix C Recommended spare parts The following tables list the recommended spare parts that would allow you to maintain a single gas chromatograph. C.
0 1 per car- rier CARRIER DRYER ASSEMBLY 2-3-0500-180 Note If a GC has a stream internal switching assembly, then one spare is recommended. Note Application dependent. Please contact your Rosemount Analytical, Inc. representative and provide the GC's sales order number for recommended part number and description.
0 1 PCA SOLENOID/HEATER DRIVER 2-3-0710-002 0 1 PCA BASE I/O 2-3-0710-003 0 1 PCA BACKPLANE 2-3-0710-005 0 1 PCA MAIN CPU 2-3-0710-007 0 1 PCA FID ELECTROMETER 2-3-0710-014 0 Note 3 ASSEMBLY, POWER SU.
Note 1 Note 1 SOLENOID, 3-WAY, 24VDC 2-4-0700-124 1 per valve 1 per valve KIT DIAPHRAGM, 10-PORT XA 2-4-0710-171 1 per valve 1 per valve KIT DIAPHRAGM, 6-PORT XA 2-4-0710-248 1 1 COLUMN SET Note 2 1 p.
Appendix D Shipping and long-term storage recommendations The following recommendations should be followed: • For shipping purposes the gas chromatograph should be secured to a wooden pallet, maintained in a vertical position and enclosed in a wood framework with a cardboard skin.
Shipping and long-term storage recommendations 184.
Appendix E Engineering drawings E.1 List of engineering drawings This addendum contains the following engineering drawings: • BE-22175 Label Set Field Wiring Card 1 (Sheets 1, 2, and 3) • DE-22050.
Engineering drawings 186.
Engineering drawings 187.
2-3-9000-744 Rev G 2014 AMERICAS Emerson Process Management Rosemount Analytical Gas Chromatograph Center of Excellence 10241 West Little York, Suite 200 Houston, TX 77040 USA Toll Free 866 422 3683 T +1 713 396 8880 (North America) T +1 713 396 8759 (Latin America) F +1 713 466 8175 gc.
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