Page 1 MODEL 1000 GAS CHROMATOGRAPH HARDWARE REFERENCE MANUAL Applies to both Daniel Danalyzer Model 1000 Rosemount Analytical Model 1000 Part Number 3-9000-541 Revision B SEPTEMBER 2005...
Page 3 ARE REGISTERED TRADEMARKS OF DANIEL INDUSTRIES, INC. THE ROSEMOUNT AND ROSEMOUNT ANALYTICAL LOGO THE ARE REGISTERED TRADEMARKS OF ROSEMOUNT ANALYTICAL, INC. THE EMERSON LOGO IS A TRADEMARK AND SERVICE MARK OF EMERSON ELECTRIC CO. COPYRIGHT © 2005 BY DANIEL MEASUREMENT AND CONTROL, INC., HOUSTON, TEXAS, U.S.A.
Page 4 MODEL 1000 SEP 2005 WARRANTY 1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise expressly provided herein, Daniel Measurement and Control, Inc. and Rosemount Analytical, Inc., (collectively “Seller”) warrants that the firmware will execute the programming instructions provided by Seller, and that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expiration of the applicable warranty period.
Page 5: Table Of Contents
MODEL 1000 SEP 2005 TABLE OF CONTENTS PURPOSE OF THIS MANUAL ........1-1 PURPOSE OF THIS MANUAL .
Page 6 MODEL 1000 SEP 2005 ANALYZER ............2-5 2.2.1 Physical Description .
Page 7 MODEL 1000 SEP 2005 PREPARATION ..........3-14 3.2.1 Introduction .
Page 8 MODEL 1000 SEP 2005 3.4.8 Controller AC-Power Wiring ......... 3-88 ANALYZER LEAK CHECKS AND PURGING FOR FIRST CALIBRATION .
Page 9 MODEL 1000 SEP 2005 MAINTENANCE ..........5-1 TROUBLESHOOTING AND REPAIR CONCEPT .
Page 10 MODEL 1000 SEP 2005 GC CONTROLLER MAINTENANCE ....... 5-31 5.6.1 GC Controller Access .
Page 11 MODEL 1000 SEP 2005 APPENDICES Appendix Page SUPPLEMENTAL WIRING GUIDE - SERIAL COMMUNICATIONS ..A-1 GC Serial Port and Cable Configurations for RS-232 ..... . A-2 RS-232 Connection from GC Controller to PC .
Page 12 MODEL 1000 SEP 2005 ADDENDA Addendum Page ANALYZER DRAWINGS ....... . . Addendum 1-1 GC CONTROLLER DRAWINGS .
Page 13: Purpose Of This Manual
SEP 2005 DESCRIPTION PURPOSE OF THIS MANUAL The Emerson Process Management Model 1000 Gas Chromatograph System Hardware Reference Manual (P/N 3-9000-541) is intended as a user's guide to accompany the MODEL 1000 GAS CHROMATOGRAPH SYSTEM. For software operation instructions, see the MON2000 Software for Gas Chromatographs User Manual (P/N 3-9000-522).
Page 14 MODEL 1000 SEP 2005 Section 4 Operation Instructions for operating the GC System by means of its built-in keyboard and liquid crystal display (LCD), if provided. Section 5 Maintenance Instructions for regular maintenance and care of the GC System hardware. Instructions for troubleshooting, repair, and service of the GC System hardware.
Page 15: Introduction
SEP 2005 INTRODUCTION The Emerson Process Management Model 1000 Gas Chromatograph is a high-speed GC system that is factory engineered to meet specific field application requirements based on stream composition and the anticipated concentration of the components of interest. The GC System typically consists...
Page 16 MODEL 1000 SEP 2005 In its standard configuration, the Model 1000 series Analyzer can handle up to five streams: typically, four for sample and one for calibration. With an optional stream switch assembly added, the GC System can switch up to twelve streams, maximum. The GC Controller, is designed to be operated primarily from a personal computer (PC) running the MON2000 software package.
Page 17: Functional Description
MODEL 1000 SEP 2005 FUNCTIONAL DESCRIPTION A functional block diagram of a typical GC System installation is shown in Figure 1-1. A sample of the gas to be analyzed is taken from the process stream by a sample probe installed in the process line.
Page 18 MODEL 1000 SEP 2005 Figure 1-1. GC System Functional Block Diagram DESCRIPTION...
Page 19: Minimum Pc Requirements
MODEL 1000 SEP 2005 MINIMUM PC REQUIREMENTS To achieve maximum performance when running the MON2000 software, ensure your PC system contains the following hardware and software equipment. • PC with a 486/90 MHz or higher processor (Pentium/100MHz or higher recommended) running: Windows®...
Page 20 MODEL 1000 SEP 2005 Microsoft Internet Explorer 5.0 is required to view spreadsheets or reports saved in HTML format. • Use the Settings>Control Panel>System>General Page menu path to check the system version number. For Windows® 95, the version number should be 4.00.950A/B or later. For Windows®...
Page 21: Modes Of Operation
MODEL 1000 SEP 2005 MODES OF OPERATION 1.5.1 User Interfaces You have at least one, and optionally two, user interfaces from which to operate the gas chromatograph (GC) system: PC connected to the GC and running MON2000 - The PC connected to the GC and running the MON2000 offers the greatest amount of capability and flexibility.
Page 22: Capabilities
MODEL 1000 SEP 2005 1.5.2 Capabilities Individual gas chromatograph Controller functions that can be initiated or controlled by the GC System and its software, MON2000, include (but are not limited to) the following: valve activations stream/calculation assignments timing adjustments diagnostics stream sequences alarm and event processing heater controls (when applicable)
Page 23: Theory Of Operation
MODEL 1000 SEP 2005 THEORY OF OPERATION See Section 1.7, the “Glossary” section of this manual, for definitions of some of the terminology used in the following explanations. 1.6.1 Analyzer Detector The Analyzer detector subsystem is a thermal conductivity detector that consists of a balanced bridge network with heat-sensitive thermistors in each leg of the bridge.
Page 24 MODEL 1000 SEP 2005 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 bridge can be balanced by the fine and coarse adjustment potentiometers located on the preamplifier circuit board.) The analysis begins when a fixed volume of sample is injected into the column by operation of the sample valve.
Page 25: 1.6.2. Data Acquisition
MODEL 1000 SEP 2005 1.6.2. Data Acquisition Every second, exactly 40 equi-spaced data samples are taken for analysis by the GC Controller (i.e., once every 25 milliseconds). Each data sample, after having been precision-amplified, is subjected to a twelve bit analog to digital (A/D) conversion. The sampling frequency of 40 Hertz (Hz) was chosen to reduce 60 Hz normal mode noise.
Page 26: Peak Detection
MODEL 1000 SEP 2005 1.6.3 Peak Detection For normal area or peak height concentration evaluation, the determination of a peak's start, peak point, and end is automatic. The manual determination of start and end points is used only for area calculations in the Forced Integration mode.
Page 27 MODEL 1000 SEP 2005 In a single peak situation, peak area is the area of the component peak between the curve and the zero reference line. The peak height is the distance from the zero reference line to the maximum point on the component curve.
Page 28: Basic Analysis Computations
MODEL 1000 SEP 2005 1.6.4 Basic Analysis Computations Two basic analysis algorithms are included in the GC Controller. These are: Area Analysis - Calculates area under component peak Peak Height Analysis - Measures height of component peak Concentration Analysis by Using Response Factor Concentration calculations require a unique response factor for each component in an analysis.
Page 29 MODEL 1000 SEP 2005 Average response factor is calculated as follows: Where: RFAVG Area or height average response factor for component “n” Area or height response factor for component “n” from the calibration Number of calibration runs actually used to calculate the response factors The percent deviation of new RF averages from old RF average is calculated in the following manner:...
Page 30 MODEL 1000 SEP 2005 Note that the average concentration of each component will also be calculated when data averaging is requested. Component concentrations may be input through analog inputs 1 - 4 or may be fixed. If a fixed value is used, the calibration for that component is the mole % that will be used for all analyses. Concentration Calculations with Normalization Where: CONCN...
Page 31: Glossary
MODEL 1000 SEP 2005 GLOSSARY Auto Zero: Automatic zeroing of the preamplifier. May be entered into the Controller to take place at any time during the analysis when either the component is not eluting or the baseline is steady. Chromatogram: A permanent record of the detector output. A chromatograph is obtained from a PC interfaced with the detector output through the GC Controller.
Page 32 MODEL 1000 SEP 2005 Response Factor: Correction factor for each component as determined by the calibration. It is defined by the equation: Where: = Area response factor for component “n” in area per mole percent (%) = Height response factor for component “n” Area = Area associated with component “n”...
Page 33: Equipment Description
MODEL 1000 SEP 2005 EQUIPMENT DESCRIPTION This section provides descriptions of the various subsystems and components that make up the Model 1000 Gas Chromatograph System. This section is organized as follows: Sampling System ..........See Section 2.1 Sampling Point Location .
Page 34: Sampling System
MODEL 1000 SEP 2005 SAMPLING SYSTEM A well designed, properly adjusted sampling system is essential to optimum performance of any gas chromatograph. If a good sample is not obtained for analysis, the whole purpose of the system is compromised. The purpose of the sample handling system is to transfer a conditioned fluid sample that is compatible with gas chromatography requirements.
Page 35: Sample Conditioning
MODEL 1000 SEP 2005 Typically, pressure is reduced at the sample point with a pressure regulating sample probe. The input pressure to the Analyzer can be adjusted between 10 and 20 pounds per square inch, gauge (psig). Reducing the pressure at the sample point avoids the problem of heavy liquid dropout in the sample line during cold weather.
Page 36: Valving
MODEL 1000 SEP 2005 2.1.5 Valving A block valve should be installed immediately downstream of the sample takeoff point to permit shutdown of the system for maintenance. Block valves should be either gate valves or cocks of the proper material and packing, and should be rated for the process line pressure. Tight seating of all connections is essential.
Page 37: Analyzer
MODEL 1000 SEP 2005 ANALYZER 2.2.1 Physical Description The Analyzer is physically divided into two major sections (see Figure 2-1). The upper section contains the following components: • Pneumatically actuated valves that control the flow of the sample and carrier gases •...
Page 38 MODEL 1000 SEP 2005 Figure 2-1. Analyzer Components EQUIPMENT DESCRIPTION...
Page 39: Chromatograph Valves
MODEL 1000 SEP 2005 2.2.2 Chromatograph Valves A chromatograph valve is shown in Figure 2-2 in exploded view. Its pistons are pneumatically actuated in both switching directions by the actuating assemblies located below the primary plate. Figure 2-2. Chromatograph Valve EQUIPMENT DESCRIPTION...
Page 40: Primary Plate
MODEL 1000 SEP 2005 2.2.2.1 Primary Plate The primary plate contains precisely machined internal passages that enter and exit the valve at top ports, each of which is connected to the top and/or bottom of the plate within the valve. The primary plate, which is the only metallic element that comes in contact with the sample, is isolated from the remainder of the valve by specially formulated diaphragms.
Page 41: Analyzer Specifications
MODEL 1000 SEP 2005 2.2.5 Analyzer Specifications Power Requirements: 120 volts, alternating current (VAC), +10/-15VAC; 50 to 60 Hertz (Hz); single phase; 10 amperes (A) (maximum during warmup) (additional 10 amps if unit has a Sample System Oven). Ambient Temperature Range: -18 degrees Celsius (°C) to +55°C (0°F to +130°F) Humidity: 0 to 95 percent relative humidity, noncondensing Vibration: Designed for mounting on process piping or other field structures subject to normal process vibrations...
Page 42: Utility Gas Requirements
MODEL 1000 SEP 2005 2.2.6 Utility Gas Requirements Carrier Gas: Application dependent, typically zero grade helium, hydrogen or nitrogen (99.995% pure, with less than 5 ppm water, and less than 0.5 ppm hydrocarbons); pressure is variable. Valve Actuation Gas: typically zero grade, 99.995% pure helium at 100 psig. Consumption is 100cc per analysis cycle.
Page 43: Controller Hardware Configurations
MODEL 1000 SEP 2005 2.3.1 Controller Hardware Configurations The GC Controller may be provided for hazardous area mounting, 19-inch rack mounting, or used in a 12-inch rack retrofit kit. See Figure 2-3. The unit consists of an STD-bus based computer and related boards, including boards for terminating field wiring.
Page 44: Analog Inputs And Outputs
MODEL 1000 SEP 2005 For operating a printer (in a nonhazardous area) at the GC Controller site, a DB-25 parallel port is available on the GC Controller's Terminal Board (TB) for field wiring. For connecting a PC to the GC Controller at the GC Controller site (for setup, operation, or maintenance in a nonhazardous area), a DB-9 serial port connector is available on the Controller's front panel.
Page 45: Digital Inputs And Outputs
MODEL 1000 SEP 2005 2.3.1.2 Digital Inputs and Outputs The Controller has the capability of sixteen digital inputs used as follows: 5 - to read a Modbus address, as defined by DIP switch positions. 2 - to indicate presence and type of front panel as defined by switch positions 1 - Spare 1 - temperature sensor input to shut off LCD backlight 1 - GC alarm, optically isolated, with transient protection...
Page 46: Driver Outputs
MODEL 1000 SEP 2005 2.3.1.4 Driver Outputs The GC Controller has eight stream switch outputs, 120 mA continuous current, which can be used to control optional AC or DC solenoid switch boards. This increases stream switch capability from the standard capability of four gas streams and 1 calibration gas (CAL) system to a maximum capability of twelve streams.
Page 47: Electrical/Mechanical Safety And Integrity - Certifications And Classifications
MODEL 1000 SEP 2005 2.3.1.6 Electrical/Mechanical Safety and Integrity - Certifications and Classifications: Both the Analyzer electronics and the GC Controller, when housed inside a purged enclosure, meet these certifications and classifications for electrical and/or mechanical safety and integrity: National Electrical Manufacturers Association (NEMA) 7 for National Electrical Code (NEC) Class I, Division 1, Groups C and D areas.
Page 48: Gc Controller Circuit Board List
MODEL 1000 SEP 2005 Both the Analyzer, when housed inside a purged enclosure, and the GC Controller, when housed inside (a) the purged enclosure, (b) the rack mount enclosure, or the retrofit enclosure, meet the following classification for control against excessive radio frequency (RF) emissions: Federal Communications Commission (FCC) Part 15, Subparts A and B 2.3.1.7 GC Controller Circuit Board List...
Page 49 MODEL 1000 SEP 2005 The inserted circuit boards of the GC Controller perform these functions (see Table 2-2): Table 2-2. Functions of Inserted Circuit Boards, GC Controller Card Cage Assembly Handle Label See drawing Subsystems or Part Number Function(s) number... CPU microprocessor MCM/LPM-6117 Microprocessor;...
Page 50 MODEL 1000 SEP 2005 There are two circuit boards attached to the outside of the card cage: the System Interface and Driver Board, and the GC Controller's Terminal Board for Field Wiring. The GC Controller's Terminal Board for Field Wiring provides termination connections for these items: Communication ports (COM1, COM2, COM3, COM4, COM5, COM6, COM7, and COM8),...
Page 51 MODEL 1000 SEP 2005 The System Interface and Driver Board provides these functions: Drivers for switching the eight optional valve solenoids, Location for 8-position DIP switch to set the Modbus address, Opto-isolation circuits for the discrete inputs and outputs, Switching power supply and temperature shutdown circuit for the LCD display, RS-232 to RS-422 conversion for the LCD display, and Voltage-to-current conversion for the analog outputs.
Page 52 MODEL 1000 SEP 2005 Figure 2-5. Block Diagram of GC Controller Circuit Boards 2-20 EQUIPMENT DESCRIPTION...
Page 53: Optional Keyboard And Display
MODEL 1000 SEP 2005 2.3.2 Optional Keypad and Display A keypad and liquid crystal display (LCD), optionally built into the enclosure's front panel, are available for the purged and rack mount versions of the GC Controller. The built-in keypad and LCD are especially useful for the purged version.
Page 54: Status Indicators
MODEL 1000 SEP 2005 2.3.3.1 Status Indicators Three colored LED status indicators are located at the side of the display on the front panel. The indicators are arranged from yellow, green, and red. When illuminated, the LED status indicators signify the following: Yellow LED: When illuminated, the Yellow LED indicates that an out-of-tolerance value or an alarm condition was entered into the Controller memory for printout with the analysis.
Page 55: Installation And Setup
MODEL 1000 SEP 2005 INSTALLATION AND SETUP This section provides instructions for installing and setting up the Model 1000 Gas Chromatograph system. This section is organized as follows: Because the Model 1000 Gas Chromatograph system is available in different configurations, not all of the instructions in this section may apply.
Page 56 MODEL 1000 SEP 2005 Before Connecting ..........3.4.3.1 PC-to-GC, Front Panel Quick and Easy RS-232 .
Page 57 MODEL 1000 SEP 2005 Table 3-1. Summary of Installation and Setup Steps Observe Precautions and Warnings see Section 3.1 Plan Site Location see Section 3.2 Obtain Supplies and Tools see Section 3.2 Install Analyzer Wiring see Section 3.3 Install Analyzer Sample & Gas Lines see Section 3.3 Install GC Controller Wiring see Section 3.4...
Page 58: Precautions And Warnings
PRECAUTIONS AND WARNINGS The Analyzer electronics and GC Controller, when housed inside a purged enclosure meet the certifications and classifications identified in Section 2.3.1.6, this manual. Emerson Process Management does not, however, accept any responsibility for installations of these, or any attached equipment, in which the installation or operation thereof has been performed in a manner that is negligent and/or non-compliant with applicable safety requirements.
Page 59 MODEL 1000 SEP 2005 Follow these precautions if installing or operating the Model 1000 Analyzer instrumentation in a hazardous area: Install and operate only the purged version of the GC Controller in a hazardous area. Do not operate in a hazardous area any printer or personal computer (PC) that is connected to the GC Controller.
Page 60: Power Source Wiring
MODEL 1000 SEP 2005 3.1.2 Power Source Wiring Observe Precautions and Warnings Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring Follow these precautions when installing AC power source wiring to the Model 1000 Analyzer instrumentation: All wiring must conform to the National Electric Code, local state or other jurisdiction, and company standards and practices.
Page 61: Signal Wiring
MODEL 1000 SEP 2005 3.1.3 Signal Wiring Observe Precautions and Warnings Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring Follow these general precautions for field wiring digital and analog input/output (I/O) lines: Metal conduit must be used for all process signal wiring. Metal conduit used for process signal wiring must be grounded at conduit support points (grounding the conduit at multiple points helps prevent induction of magnetic loops between the conduit and cable shielding).
Page 62 MODEL 1000 SEP 2005 When inductive loads (relay coils) are driven by digital output lines, the inductive transients must be diode clamped directly at the coil. Any auxiliary equipment wired to the GC Controller must have its signal common isolated from earth/chassis ground.
Page 63: Electrical And Signal Ground
MODEL 1000 SEP 2005 3.1.4 Electrical and Signal Ground Observe Precautions and Warnings Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring Follow these general precautions for grounding electrical and signal lines: For shielded signal conducting cables, shield-drain wires must not be more than two AWG sizes smaller than the conductors for the cable.
Page 64 MODEL 1000 SEP 2005 The equipment-grounding conductors used between the GC Controller and the copper-clad steel ground rod must be sized according to the following specifications: length, 15 feet or less AWG 8, stranded, insulated copper wire (4.6 meters) length, 15 to 30 feet AWG 6, stranded, insulated copper wire (4.6 to 9.1 meters) length, 30 to 100 feet...
Page 65: Electrical Conduit
MODEL 1000 SEP 2005 3.1.5 Electrical Conduit Observe Precautions and Warnings Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring Follow these general precautions for conduit installation: Conduit cutoffs must be square. Cutoffs must be made by a cold cutting tool, hacksaw, or by some other approved means that does not deform the conduit ends or leave sharp edges.
Page 66 MODEL 1000 SEP 2005 EQUIPMENT DAMAGE OR PERSONAL INJURY Consult your company's policies and procedures and other applicable requirements documents to determine wiring and installation practices that are appropriate for hazardous areas. Failure to do so may cause personal injury or damage to equipment. 3-12 INSTALLATION AND SETUP...
Page 67: Sample Systems Requirements
MODEL 1000 SEP 2005 3.1.6 Sample Systems Requirements Observe Precautions and Warnings Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring Observe the following guidelines for installing GC sample systems: Sample Line Length: If possible, avoid long sample lines. In case of a long sample line, flow velocity can be increased by decreasing downstream pressure and using by-pass flow via a speed loop.
Page 68: Preparation
MODEL 1000 SEP 2005 PREPARATION 3.2.1 Introduction Your Model 1000 Analyzer was started and checked out before it left the factory. Program parameters were installed in the system and documented in the “PC Config Report” furnished with your GC System. 3.2.2 Site Selection Observe Precautions and Warnings...
Page 69: Unpacking The Unit
Next, complete a full report of the nature and extent of the damage and forward the report immediately to Daniel Measurement Services (DMS), a division of Emerson Process Management for further instructions. Include complete model number information.
Page 70: Necessary Tools And Components
MODEL 1000 SEP 2005 3.2.4 Necessary Tools and Components Observe Precautions and Warnings Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring Observe the following checklist of tools and components that you will need for installing the Analyzer and GC Controller: Chromatographic grade carrier gas: zero grade helium or nitrogen (99.995% pure, with less than 5 ppm water, and less than 0.5 ppm hydrocarbons).
Page 71 MODEL 1000 SEP 2005 ® Liquid leak detector (SNOOP or equivalent). (10) Digital volt-ohm meter with probe-type leads. (11) A flow measuring device such as Alltech Digital Flow Check™ Flowmeter. 3-17 INSTALLATION AND SETUP...
Page 72: Optional Tools And Components
MODEL 1000 SEP 2005 3.2.5 Optional Tools and Components Observe Precautions and Warnings Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring Observe the following checklist of tools and components you may need for installing and using the GC System: For operation in a nonhazardous area only: Printer and printer paper.
Page 73 MODEL 1000 SEP 2005 Serial Cable Specifications: Straight-through serial cable with the following terminations: DB-9, male connects to GC Controller external serial port DB-9 or DB-25, female connects to PC serial port Interconnect Cable, P/N 6-4618-122, if not already installed between the Analyzer and GC Controller.
Page 74: Installing The Analyzer
MODEL 1000 SEP 2005 INSTALLING THE ANALYZER 3.3.1 Point-to-point Wiring Guide, Analyzer-controller Observe Precautions and Warnings Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring This section applies only to GC systems which have not been shipped "prewired." In most cases, the purged system will already have had the Analyzer-Controller connections made.
Page 75 MODEL 1000 SEP 2005 Figure 3-1. Behind the Valve Driver Board is the Interconnect Board Containing TB-4 Loosen and remove the four (4) thumbscrews that hold the Valve Driver Board. Carefully edge the Valve Driver Board off the holding screws. Do not disconnect the Valve Driver Board from the cable;...
Page 76 MODEL 1000 SEP 2005 Figure 3-2. Valve Driver Board Resting Face Down from its Cable Allows Access to TB-4 3-22 INSTALLATION AND SETUP...
Page 77 MODEL 1000 SEP 2005 Table 3-2. Point-to-Point Wiring Guide, Analyzer and GC Controller Board Acronyms: Interconnect Terminal Board of Analyzer (TB-4) Terminal Board for Field Wiring at Controller (TB) Analyzer Controller (TB-4) color color (TB) Terminal 11 Function code 1 J19, Terminal 1 Terminal 12 Function code 2...
Page 78 MODEL 1000 SEP 2005 EQUIPMENT DAMAGE OR PERSONAL INJURY Do not apply AC electrical power to the Analyzer or the GC Controller until all electrical power, interconnection, and external signal connections have been verified, and proper grounds have been made. Refer to Section 3.1.3 for general precautions concerning signal wiring.
Page 79 MODEL 1000 SEP 2005 Figure 3-3. Analyzer and GC Controller Interconnect Leads 3-25 INSTALLATION AND SETUP...
Page 80 MODEL 1000 SEP 2005 After confirming that all Interconnect Cable terminations are correct between the Analyzer and the GC Controller, lift the Valve Driver Board from its resting position and place it over the four holding screws. Reinstall the four thumb screws to secure the Valve Driver Board in place. If necessary, complete wiring connections between the Analyzer's Valve Driver Board and any optional stream switch boards.
Page 81: Analyzer Ac-Power Wiring
MODEL 1000 SEP 2005 3.3.2 Analyzer Ac-power Wiring Observe Precautions and Warnings Plan Site Location Obtain Supplies and Tools Install Analyzer Wiring To connect 115 volts AC-Power to the Analyzer, follow these steps: Locate the three leads for connecting 115 volts AC-power to the Analyzer. Leads are "pig-tailed"...
Page 82 MODEL 1000 SEP 2005 EQUIPMENT DAMAGE OR PERSONAL INJURY Do not apply AC electrical power to the Analyzer or the GC Controller until all electrical power, interconnection, and external signal connections have been verified, and proper grounds have been made. Failure to properly connect the GC unit may result in serious equipment damage or personal injury.
Page 83: Sample And Gas Lines
MODEL 1000 SEP 2005 3.3.3 Sample and Gas Lines Install Analyzer Wiring Install Analyzer Sample & Gas Lines Install GC Controller Wiring Perform Leak Checks To install GC sample and gas lines, follow these steps: Use stainless steel tubing. Keep tubing clean and dry internally to avoid contamination. Before connecting the sample and gas lines, flow clean air or gas through them.
Page 84 MODEL 1000 SEP 2005 Connect carrier gas to Analyzer. (DO NOT TURN ON GAS AT THIS TIME.) See Appendix B, this manual, for a description of a dual-cylinder carrier gas manifold (P/N 3-5000-050) with these features: Carrier gas is fed from two bottles. When one bottle is nearly empty (100 psig), the other bottle becomes the primary supply.
Page 85 MODEL 1000 SEP 2005 Connect sample gas stream(s) to Analyzer. (DO NOT TURN ON GAS AT THIS TIME.) Use 1/8-inch or 1/4-inch stainless steel tubing to conduct calibration standard gas. Ensure that pressure of sample line is regulated to maintain 15-30 psig ±10%. Sample gas stream inlet(s) are identified in the applicable Sample Conditioning System ("S.C.S") drawing in the Analyzer drawings addendum to this manual.
Page 86: Installing The Gc Controller
MODEL 1000 SEP 2005 INSTALLING THE GC CONTROLLER 3.4.1 Modbus Slave Address (COM ID) Setup Install Analyzer Wiring Install Analyzer Sample & Gas Lines Install GC Controller Wiring Perform Leak Checks The GC Controller's COM ID is determined by dual inline package (DIP) switch settings. In most cases, the COM ID setup made at the factory will not require changes.
Page 87 MODEL 1000 SEP 2005 To inspect or change the GC Controller's COM ID setup, follow these steps: At the GC Controller site, locate the DIP switch as described in the following steps. SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Before removing the unit cover from the GC Controller, make certain the power supply switch is OFF and the AC power cord is disconnected.
Page 88 MODEL 1000 SEP 2005 Inspect or change the DIP switch settings as necessary. See Table 3-3 as a guide. Make sure you record in the GC Controller's maintenance records any changes you make to the switch settings. Figure 3-5. COM ID DIP Switch Explanation of DIP Switch Setting Switches "1"...
Page 89 MODEL 1000 SEP 2005 Table 3-3. Modbus Slave Address (COM ID) DIP Switch Settings Dip Switch Settings Switch Positions COM ID RAM CLEAR Dip Switch Setting Switch Positions Clears RAM when unit powered down Keeps RAM when unit powered down When finished with the inspection or changes, reassemble the Controllers using the following steps.
Page 90: Controller-Analyzer Wiring
MODEL 1000 SEP 2005 3.4.2 Controller-Analyzer Wiring Install Analyzer Wiring Install Analyzer Sample & Gas Lines Install GC Controller Wiring Perform Leak Checks This section applies only to GC systems which have not been shipped "prewired." In most cases, the purged system will already have had the Controller-Analyzer connections made. If your system has already been wired, skip this section, and proceed to the next section.
Page 91 MODEL 1000 SEP 2005 For the explosion-proof Controller, the front panel is secured by 16 screws. Remove those screws first. Then carefully lower the front panel on its bottom hinges. The front panel is heavy, so make sure it does not drop and cause damage. For the rack mount Controller, the rear of the enclosure is open;...
Page 92: Controller-Pc Wiring (Serial Connections)
MODEL 1000 SEP 2005 3.4.3 Controller-PC Wiring (Serial Connections) Install Analyzer Wiring Install Analyzer Sample & Gas Lines Install GC Controller Wiring Perform Leak Checks A preferred method for operating a Model 1000 GC System is from a connected personal computer (PC).
Page 93 MODEL 1000 SEP 2005 You will need to connect the GC Controller to one of the PC's available, or unused serial ports. To determine which PC serial ports are already being used by other equipment and which port can be used for connecting to the GC Controller, note existing serial connections, refer to your PC user's manual, and use diagnostic software (such as Norton Utilities™).
Page 94 MODEL 1000 SEP 2005 COM8 is used for the display/keypad when unit has COM5-8 option (COM4A Board). However, when the unit has a display/keypad but does not have the COM8 option, COM4 must be RS-232, and is used for the display/keypad. Therefore, there is no COM4 output on the field terminal board.
Page 95 MODEL 1000 SEP 2005 3.4.3.2 PC-to-GC, Front Panel Quick and Easy RS-232 The easiest way to connect a PC to the GC Controller is with an 'off-the-shelf', straight-through serial cable connected to the GC Controller's front panel DB-9 serial port jack. To connect a PC to the GC Controller's front panel DB-9 serial port jack, proceed as follows: SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Do not operate a PC in a hazardous environment.
Page 96 MODEL 1000 SEP 2005 3.4.3.3 PC-to-GC, Permanent Cable Connection for Short Distance RS-232 Another way to connect a PC to the GC Controller is with straight-through serial cable connected to one of the GC Controller's internal serial ports located on the Controller's Terminal Board for Field Wiring (TB).
Page 97 MODEL 1000 SEP 2005 Another option is to use a Direct Serial Connect Cable (P/N 3-2350-068), or fabricate one like it. Connect the DB-9 female plug end to the DB-9 male serial port on the PC. Connect the cable's exposed leads to the GC serial port on the TB. When the DB-9 female plug of the cable is connected to a standard PC, its six leads will be configured for RS-232 as shown in Table 3-4.
Page 98 MODEL 1000 SEP 2005 3.4.3.4 PC-to-GC, Long Distance with RS-422 or RS-485 RS-422 and RS-485 serial protocols are recommended for longer distance serial connections between the PC and GC System (i.e., distances greater than the 50 feet). To connect a PC to one of the GC Controller's internal serial port jacks that accept RS-422 or RS-485 serial protocol, proceed as follows: Obtain the following equipment: An asynchronous line driver / interface device with RS-232 input, and RS-422 or RS-...
Page 99 MODEL 1000 SEP 2005 Choose an available serial port on the TB that is configured for RS-422 or RS-485 serial protocol, and connect the twisted pair cable from the line driver. (See Appendix A, this manual, for example connection.) (Also see Section 3.4.4, this manual for list of ports and terminals assigned to serial communications.) When the unit has the COM4A Board installed, COM8 is used for the display/keyboard.
Page 100: Cpu And Com4A Serial Communications Setups
MODEL 1000 SEP 2005 3.4.4 CPU and COM4A Serial Communications Setups Install Analyzer Wiring Install Analyzer Sample & Gas Lines Install GC Controller Wiring Perform Leak Checks The GC Controller has four serial communications channels: COM1, COM2, COM3, and COM4. Through jumper settings, they can be configured for the following serial signal definitions: RS-232, RS-422, or RS-485.
Page 101 MODEL 1000 SEP 2005 The front panel serial port on the GC Controller is configured for RS-232, by default, and is connected to the Controller's serial port COM1. Consequently, the Controller's COM1 is usually reserved for direct serial communication between the Controller and a PC. A telephone Modem Board plugs into the COM4A Board and can be configured for RS-232.
Page 102 MODEL 1000 SEP 2005 To connect serial communications lines to the GC Controller, follow these steps: Access the GC Controller's Terminal Board for Field Wiring (TB). If necessary, see instructions in Section 3.4.1, step (1). Route serial communications lines appropriately, especially in the case of the explosion- proof Controller enclosure.
Page 103 MODEL 1000 SEP 2005 Each of the various combinations available for GC Controller serial communications ports (i.e., RS-232, RS-422, or RS-485) require the following: Specific jumper settings on the CPU Board (P/N 20765) and COM4A Board (P/N 20766), and Specific transient protection modules on the Controller's TB. 3-49 INSTALLATION AND SETUP...
Page 104: Cpu Rs-232/Rs-422/Rs-485 Configurations
MODEL 1000 SEP 2005 3.4.4.1 CPU RS-232/RS-422/RS-485 Configurations ® The WinSystems CPU (P/N LPM/MCM-6117) provides four RS-232 serial channels onboard, configurable as RS-422 or RS-485 with the addition of optional driver IC’s. The configuration options for each of the supported modes are shown on the following pages. Figure 3-9.
Page 105: Cpu Rs-232 Configuration
MODEL 1000 SEP 2005 3.4.4.2 CPU RS-232 Configuration CPU COM1 RS-232 Configuration COM1 is I/O mapped at 3F8H and utilizes a 16550 type DART contained in the Super I/O chip. When used in RS-232 mode, COM1 is terminated via the Multi-I/O connector at J1. The configuration details and the pin definitions when used with the cable (P/N 3-2350-083) are shown here: Figure 3-10.
Page 106 MODEL 1000 SEP 2005 CPU COM3 RS-232 Configuration COM3 is I/O mapped at 3E8H and utilizes a 16550 type UART contained in the 16C532 companion chip. When used in RS-232 mode, COM3 is terminated via the connector at J6. The configuration details and the pin definitions, when used with the cable (P/N 3-2350-087), are shown here: Figure 3-12.
Page 107: Cpu Rs-422 Configuration
MODEL 1000 SEP 2005 3.4.4.3 CPU RS-422 Configuration CPU COM1 RS-422 Configuration RS-422 signal levels are supported on any, or all serial channels, with the installation of the optional "Chip Kit" (P/N 3-2350-115). This kit provides the driver IC’s necessary for a single channel of RS-422.
Page 108 MODEL 1000 SEP 2005 CPU COM2 RS-422 Configuration RS-422 signal levels are supported on any, or all serial channels, with the installation of the optional "Chip Kit" (P/N 3-2350-115). This kit provides the driver ICs necessary for a single channel of RS-422.
Page 109 MODEL 1000 SEP 2005 CPU COM3 RS-422 Configuration RS-422 signal levels are supported on any, or all serial channels, with the installation of the optional "Chip Kit" (P/N 3-2350-115). This kit provides the driver ICs necessary for a single channel of RS-422.
Page 110 MODEL 1000 SEP 2005 CPU COM4 RS-422 Configuration RS-422 signal levels are supported on any, or all serial channels, with the installation of the optional "Chip Kit" (P/N 3-2350-115). This kit provides the driver ICs necessary for a single channel of RS-422.
Page 111: Cpu Rs-485 Configuration
MODEL 1000 SEP 2005 3.4.4.4 CPU RS-485 Configuration The RS-485 multi-drop interface is supported on all serial channels with the installation of the optional "Chip Kit" (P/N 3-2350-115). A single kit is sufficient to configure two of the channels for RS-485.
Page 112 MODEL 1000 SEP 2005 CPU COM3 RS-485 Configuration Figure 3-20. COM3 RS-485 CPU COM4 RS-485 Configuration Figure 3-21. COM4 RS-485 3-58 INSTALLATION AND SETUP...
Page 113: Cpu Com1/Com2, Keyboard And Printer Output Header
MODEL 1000 SEP 2005 3.4.4.5 CPU COM1/COM2, Keyboard and Printer Output Header COM1, COM2, the keyboard, and the printer are terminated at J1. Refer to the Multi-I/O Connector, Section 3.4.4.14 and Figure 3-34 for additional information. 3.4.4.6 CPU COM3/COM4 Output Header COM3 and COM4 can be configured two different ways.
Page 114: Com4A Rs-232/Rs-422/Rs-485 Configuration
MODEL 1000 SEP 2005 3.4.4.7 COM4A RS-232/RS-422/RS-485 Configuration To configure the PCM-COM4A Board for the desired mode of operation, use the following information. Each of the 4 serial channels may be configured independently for either RS-232, RS-422, or RS- 485 signal levels. An optional "Chip Kit" (P/N 3-2350-115) is necessary to allow configuration of a single channel for RS-422 use or up two channels of RS-485 usage.
Page 115 MODEL 1000 SEP 2005 Channel 1 - I/O Connector J6 Figure 3-23. Channel 1 - I/O Connector J6 3-61 INSTALLATION AND SETUP...
Page 116 MODEL 1000 SEP 2005 Channel 2 - I/O Connector J6 Figure 3-24. Channel 2 - I/O Connector J6 3-62 INSTALLATION AND SETUP...
Page 117 MODEL 1000 SEP 2005 Channel 3 - I/O Connector J3 Figure 3-25. Channel 3 - I/O Connector J3 3-63 INSTALLATION AND SETUP...
Page 118 MODEL 1000 SEP 2005 Channel 4 - I/O Connector J3 Figure 3-26. Channel 4 - I/O Connector J3 3-64 INSTALLATION AND SETUP...
Page 119: Com4A Rs-232 Configuration
MODEL 1000 SEP 2005 3.4.4.8 COM4A RS-232 Configuration Ports: Maximum number of RS-232 ports available: seven (see Section 3.4.5), which are routed to DB-9 plug connections (female): P2 (COM1) and P3 (COM2); or P22 (COM5), P23 (COM6), P24 (COM7). Phoenix plug connections (or bare-wire) connections: GC Controller TB, J5 (COM1), J6 (COM2), J10 (COM3), and J11 (COM4).
Page 120 MODEL 1000 SEP 2005 RS-232 Terminal Board for Field Wiring at Controller (TB) P22 (COM5) Terminal 1 P23 (COM6) Terminal 2 (TxD) P24 (COM7) Terminal 3 S (RxD) Terminal 4 Terminal 5 Terminal 6 Terminal 7 Terminal 8 Terminal 9 3-66 INSTALLATION AND SETUP...
Page 121 MODEL 1000 SEP 2005 RS-232 (continued) Terminal Board for Field Wiring at Controller (TB) P2 (COM1) Terminal 1 RLSD (DCD) Terminal 2 (TxD) P3 (COM2) Terminal 3 S (RxD) Terminal 4 Terminal 5 Terminal 6 Terminal 7 NOTE: DB-9 plug on GC Controller is wired to Terminal 8 eliminate the need for a null-...
Page 122 MODEL 1000 SEP 2005 RS-232 (continued) Terminal Board for Field Wiring at Controller (TB) P22 (COM5) Terminal 1 P23 (COM6) Terminal 2 (TxD) P24 (COM7) Terminal 3 S (RxD) Terminal 4 Terminal 5 Terminal 6 Terminal 7 NOTE: DB-9 plug on GC Controller is wired to Terminal 8 eliminate the need for a null-...
Page 123: Com4A Rs-422 Configuration
MODEL 1000 SEP 2005 3.4.4.9 COM4A RS-422 Configuration Ports: Maximum number of RS-422 ports available: five (see Section 3.4.5), which are routed to DB-9 plug connections (female): P3 (COM2), P22 (COM5), P23 (COM6), P24 (COM7); or Phoenix plug (or bare-wire) connections: GC Controller TB, J6 (COM2) and J10 (COM3).
Page 124 MODEL 1000 SEP 2005 RS-422 (continued) Terminal Board for Field Wiring at Controller (TB) P3 (COM2) Terminal 2 Terminal 3 Terminal 4 Terminal 5 Terminal 8 RS-422 (continued) Terminal Board for Field Wiring at Controller (TB) P22 (COM5) Terminal 2 P23 (COM6) P24 (COM7) Terminal 3...
Page 125: Com4A Rs-485 Configuration
MODEL 1000 SEP 2005 3.4.4.10 COM4A RS-485 Configuration Ports: Maximum number of RS-485 ports available: seven (see Section 3.4.5), which are routed to DB-9 plug connections (female): P2 (COM1), P3 (COM2), P22 (COM5), P23 (COM6), P24 (COM7); or Phoenix plug connections (or bare-wire) connections: GC Controller TB, J5 (COM1), J6 (COM2), J10 (COM3), and J11 (COM4 for RS- 485).
Page 126 MODEL 1000 SEP 2005 RS-485 (continued) Terminal Board for Field Wiring at Controller (TB) P2 (COM1) Terminal 2 RxTx P3 (COM2) P22 (COM5) P23 (COM6) Terminal 3 RxTx+ P24 (COM7) Terminal 5 3-72 INSTALLATION AND SETUP...
Page 127: Parallel Printer Interface
MODEL 1000 SEP 2005 3.4.4.11 Parallel Printer Interface The CPU (LPM/MCM-6117) supports a standard parallel printer port. The parallel port connected via cable (P/N 3-2350-083) routes the signals from the CPU Board to the System Interface Board. The parallel printer cable (customer supplied) is connected to J1 on the Field Termination Board. Figure 3-27.
Page 128: P/C104 Bus Interface
MODEL 1000 SEP 2005 3.4.4.12 PC/104 Bus Interface The CPU (LPM/MCM-6117) supports I/O expansion through the standard PC/104 Bus connectors at J19 and J20. The CPU supports both 8-bit and 16-bit PC/104 Bus modules. The PC/104 Bus connector pin definitions are provided here for reference. Figure 3-28.
Page 129: Silicon Disk Configuration
MODEL 1000 SEP 2005 3.4.4.13 Silicon Disk Configuration The GC uses the M-Systems' Disk OnChip (DOC) device as a Solid State Disk drive. This section documents the required hardware configuration for the DiskOnChip device used for the GC. The Silicon disk array is memory mapped into a 32K byte hole at segment E800H and has an I/O control register at TECH.
Page 130 MODEL 1000 SEP 2005 Silicon Disk Mode The GC uses the M-Systems DiskOnChip (DOC) device. The mode is controlled via pins 13-14 on jumper block at J11 as shown here: Figure 3-30. DiskOnChip Jumper Block Jumpering for DOC mode with EPROM, RAM, or FLASH installed effectively acts to disable the Solid State Disk and similarly, when a DOC device is installed and the jumper is selected for standard devices the DOC is disabled.
Page 131: Multi-I/O Connector
MODEL 1000 SEP 2005 3.4.4.14 Multi-I/O Connector Figure 3-32. Multi-I/O Connector The I/O to the serial channels, the printer port, and keyboard are all terminated via the connector at J1. A cable (P/N 3-2350-083) plugs into the 50-pin connector. 3-77 INSTALLATION AND SETUP...
Page 132: Parallel I/O Configuration
MODEL 1000 SEP 2005 3.4.4.15 Parallel I/O Configuration Figure 3-33. Parallel I/O Configuration ® The CPU (LPM/MCM-6117) utilizes the WinSystems WS16C48 ASIC high-density I/O chip mapped at a base address of 120H. The first 24 lines are capable of fully latched event sensing with sense polarity being software programmable.
Page 133 MODEL 1000 SEP 2005 Parallel I/O Connectors The 48 lines of parallel I/O are terminated through two 50-pin connectors at J7 and J4. The J7 connector handles I/O ports 0-2 while J4 handles ports 3-5. The pin definitions for J7 and J4 are shown here: Figure 3-34.
Page 134 MODEL 1000 SEP 2005 Parallel I/O VCC Enable The I/O connectors can provide +5 volts to an I/O rack or for miscellaneous purposes by jumpering J2. When J2 is jumpered +5 volts are provided at pin 49 of both J4 and J7. It the user's responsibility to limit current to a safe value (less than 1A) to avoid damaging the CPU Board.
Page 135: Controller-Printer Wiring
MODEL 1000 SEP 2005 3.4.5 Controller-Printer Wiring Install Analyzer Wiring Install Analyzer Sample & Gas Lines Install GC Controller Wiring Perform Leak Checks A printer can be connected directly to the GC Controller at either the Controller's parallel printer port or one of the Controller's serial ports.
Page 136 MODEL 1000 SEP 2005 If necessary, see instructions in Section 3.4.1, step (3). Locate the DB-25 female parallel printer port on the TB. It is labeled "P1". Use a standard parallel printer cable (customer supplied) for making the connection between the GC Controller and the printer's parallel port.
Page 137: Discrete (Digital) I/O Wiring
MODEL 1000 SEP 2005 3.4.6 Discrete (Digital) I/O Wiring Install Analyzer Wiring Install Analyzer Sample & Gas Lines Install GC Controller Wiring Perform Leak Checks To connect digital signal input/output lines to the GC Controller, follow these steps: Access the GC Controller's Terminal Board for Field Wiring (TB). Route digital I/O lines appropriately.
Page 138 MODEL 1000 SEP 2005 For digital input signals, also make these "jumper-wire" connections (see Figure 3-36): Jumper terminals #4 and #6 (common) on "J7". To enable digital input, apply to terminal #5, on "J7", either 12 or 24 volts DC: 12 volts is DC available from the GC Controller's power supply by jumpering terminal #2 to terminal #5 (see NOTE, below, and Figure 3-36).
Page 139 MODEL 1000 SEP 2005 Jumpering terminal #2 to terminal #5, for 12 volts DC power to enable digital input, is now done at the factory. You should not have to make this "jumper-wire" connection for a GC Controller that was built after March 1996. For high-current digital output, also install a special transient protection module (TPM), P/N 3-2350-019, in TPM socket M8, Terminal Board for Field Wiring, rear side of board.
Page 140: Analog I/O Wiring
MODEL 1000 SEP 2005 3.4.7 Analog I/O Wiring Install Analyzer Wiring Install Analyzer Sample & Gas Lines Install GC Controller Wiring Perform Leak Checks To connect analog signal input/output lines to the GC Controller, follow these steps: Access the GC Controller's Terminal Board for Field Wiring (TB). Route analog I/O lines appropriately.
Page 141 MODEL 1000 SEP 2005 As an option, the 2350A GC Controller can be configured with additional analog outputs (there are two analog outputs on the standard Analog Board, P/N 3-2350-041). For more analog outputs, the existing "Analog" board must be exchanged for one of these optional Analog Boards, allowing a quantity of either six or ten analog outputs (see drawing BE-18044 in the GC Controller drawings addendum, this manual): Analog I/O - (6) analog outputs (P/N 3-2350-039)
Page 142: Controller Ac-Power Wiring
MODEL 1000 SEP 2005 3.4.8 Controller AC-Power Wiring Install Analyzer Wiring Install Analyzer Sample & Gas Lines Install GC Controller Wiring Perform Leak Checks To connect 115 or 130 volts AC-Power to the GC Controller, follow these steps: SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Do not connect AC power leads without first ensuring that AC power source is switched OFF.
Page 143 MODEL 1000 SEP 2005 Ensure that the power source leads are properly connected to the HOT, NEUTRAL, and GROUND terminals. (Generally, the color convention for these wires is HOT - black, NEUTRAL - white, and GROUND - green.) Make power line splices and conduit seals that comply with applicable wiring requirements (for hazardous environments).
Page 144: Analyzer Leak Checks And Purging For First Calibration
MODEL 1000 SEP 2005 ANALYZER LEAK CHECKS AND PURGING FOR FIRST CALIBRATION 3.5.1 Analyzer Leak Checks Install Analyzer Wiring Install Analyzer Sample & Gas Lines Install GC Controller Wiring Perform Leak Checks To perform Analyzer leak checks, follow these steps: Plug the Measure Vent (labeled "MV") vent line if it is open.
Page 145: Purging Carrier Gas Lines
MODEL 1000 SEP 2005 3.5.2 Purging Carrier Gas Lines Perform Leak Checks Purge Carrier Gas Lines Purge Calibration Lines Start Up GC System EQUIPMENT DAMAGE OR PERSONAL INJURY Purging carrier and calibration gas lines will require that AC power be turned on to the Analyzer.
Page 146 MODEL 1000 SEP 2005 Figure 3-37. Analyzer Components 3-92 INSTALLATION AND SETUP...
Page 147 MODEL 1000 SEP 2005 Figure 3-38. Analyzer Valve Switches, Upper Enclosure Ensure that all of the Analyzer Valve Switches, upper enclosure, are set to the AUTO position. Ensure that the carrier gas bottle valve is open. Set the carrier gas line pressure at 110 psig. Use the dual stage regulator at the carrier gas bottle to adjust pressure.
Page 148: Purging Calibration Gas Lines
MODEL 1000 SEP 2005 3.5.3 Purging Calibration Gas Lines Perform Leak Checks Purge Carrier Gas Lines Purge Calibration Lines Start Up GC System To purge the calibration gas lines, as preparation for first calibration, follow these steps: Ensure that the carrier gas lines have been fully purged, as described in the previous section. Close the calibration gas bottle valve.
Page 149 MODEL 1000 SEP 2005 (13) Regulate the flow through the rotameter to approximately 50 cubic centimeters per minute (cc/min) by adjusting the metering valve on the Flow Panel. (14) Prepare for normal operation, as follows: On the Valve Driver Board, upper enclosure, reset the Stream switch "S2" to AUTO (if Stream 2 will be used for calibration gas).
Page 150: System Start-Up
MODEL 1000 SEP 2005 SYSTEM START-UP Perform Leak Checks Purge Carrier Gas Lines Purge Calibration Lines Start Up GC System To perform system start-up, follow these steps: For system start-up, run an analysis of the calibration gas. Ensure that the Stream switch for the calibration gas has been set to AUTO (see last step, previous section).
Page 151 MODEL 1000 SEP 2005 OPERATION FROM LOCAL KEYPAD AND DISPLAY You have at least one, and optionally two, user interfaces from which to operate the gas chromatograph (GC) system: PC connected to the GC and running the software program MON2000 - This user interface offers the greatest amount of capability and flexibility.
Page 152 MODEL 1000 SEP 2005 This section only addresses using the GC Controller’s built-in keypad and LCD. This section is organized as follows: Interface Components for Local Data Display and Entry ....See Section 4.1 Light Emitting Diode (LED) Indicators .
Page 153: Interface Components For Local Data Display And Entry
MODEL 1000 SEP 2005 INTERFACE COMPONENTS FOR LOCAL DATA DISPLAY AND ENTRY The components for local data display and entry are the light emitting diode (LED) indicator lights, the liquid crystal display (LCD), and the built-in keypad (see Figure 4-1). Figure 4-1.
Page 154: Liquid Crystal Display (Lcd)
MODEL 1000 SEP 2005 4.1.2 Liquid Crystal Display (LCD) The LCD measures 5.5 x 2 inches and is capable of 64 by 256 resolution, with full graphics. It is certified for use with an explosion-proof NEMA 4X, Class C and D, enclosure. The display is capable of producing the complete alphabet and numbers from the keypad.
Page 155 MODEL 1000 SEP 2005 Figure 4-2. Local Site GC Controller Keyboard Table 4-2. Local Keypad Key Strokes and Their Functions Numerals, Period (.), For entering numeric data or function codes. and Minus Sign (-) Enter (ENTER) Log on to the menu and/or move to the next field, saving the current value.
Page 156 MODEL 1000 SEP 2005 Decrement (DECR) Deletes an item from the (TEV) or (CDT) tables or used to page down in a list that covers more than one display (ALT and DECR keys). Backspace (BKSP) Deletes the character before the cursor position. Delete (DEL) Deletes the character at the cursor position (ALT and DEL keys).
Page 157: Logging On To View Or Edit Data
Type in the letters for your username, then press the ENTER key. VERY IMPORTANT Each new Emerson GC unit is shipped with one "Super-user" named EMERSON downloaded into its memory. Therefore, for the first log-on to a new GC unit, enter the USERNAME: EMERSON.
Page 158: Subsequent Log-On
Subsequent Log-On For subsequent log-on, follow these steps: If screen-saver mode is active (i.e., the screen's backlight is turned off and “Emerson" is written on the screen in various locations), then press any key on the keypad and wait 10 seconds for contrast and backlighting to take effect.
Page 159: Start / Halt An Auto Sequence Analysis
MODEL 1000 SEP 2005 4.2.3 Start / Halt an Auto Sequence Analysis To start an auto sequence analysis, proceed as follows: In the Main Menu screen, press the 5 key to select "GC Control." In the GC Control submenu screen, press the 1 key to select "Auto." At the "Auto Purge"...
Page 160 MODEL 1000 SEP 2005 To halt ongoing analysis runs, proceed as follows: In the GC Control submenu, press the 4 key to select "Halt." At the "Halt - Write Changes" prompt, press the ENTER key. (Or, to return to the GC Control submenu without halting analysis runs, press the ESC key.) When analysis runs are halted at the end of the current analysis cycle, the green LED indicator will no longer be illuminated.
Page 161: Editing Procedures
MODEL 1000 SEP 2005 4.2.4 Editing Procedures For editing, follow these guidelines: Scroll through the menu sequence to the desired data Move through menu by pressing ENTER after each correct or unchanged items or data fields term or value. Also use direction arrows. Pressing ENTER without first entering data causes the Controller to skip to the next item.
Page 162 MODEL 1000 SEP 2005 All time entries are in seconds to the nearest 1/10 Make time entries second. Press 5 (GC Control) and then 4 (HALT) to stop after Stop analysis runs the present run. Never edit the program during an analysis run from which data is to be used. Editing may cause analysis errors for that particular run.
Page 163: Validity Checks Of Data Entries
MODEL 1000 SEP 2005 4.2.5 Validity Checks of Data Entries The GC Controller compares each operator entry with preprogrammed range and format requirements. The Controller does not allow an unacceptable parameter to be entered, such as an entry that is out of range or has wrong units (e.g., a letter instead of a number). If an unacceptable parameter has been entered, enter a new or valid parameter.
Page 164: Local Display Menus
MODEL 1000 SEP 2005 LOCAL DISPLAY MENUS The local display Main Menu has seven items listed, each of which branches into another menu. This is illustrated below in the menu tree diagram, Figure 4-4, and explained further in the sections that follow.
Page 165: Main Menu
MODEL 1000 SEP 2005 4.3.1 Main Menu The Main Menu serves as the entry point into all submenus below it. Main Menu Hardware Operator Entries Alarms Chromatogram GC Control Data Records Config Rpt-Maint. Log 4.3.2 Hardware Menu The various submenus of the HARDWARE menu allow an oprator to define the stream functions, analog inputs/outputs, discrete inputs/outputs, adjust the scales and range of the inputs/outputs (within limits), set the valves, and view the Gain Ratio Indicators (GRI) from the Analyzer.
Page 166: 4.3.3 Operator Entries Menu
MODEL 1000 SEP 2005 4.3.3 Operator Entries Menu The submenus of the OPERATOR ENTRIES menu enable an operator to adjust and refine the entries normally specified in the application as it leaves the factory. Modifications may be made in entries from the Component Data Table (CDT), Retention Times (RT), Response Factors (RF), etc. for various components and streams.
Page 167: 4.3.5 Chromatogram Menu
MODEL 1000 SEP 2005 4.3.5 Chromatogram Menu The CHROMATOGRAM menu allows the operator to view a live chromatogram while the GC System is conducting analysis runs. Chromatogram Live 4.3.6 GC Control Menu The GC CONTROL menu enables the operator to stop, calibrate, or place on automatic control a sample stream from the Analyzer.
Page 168: Data Records Menu
MODEL 1000 SEP 2005 4.3.7 Data Records Menu The DATA RECORDS submenu will be particularly helpful to maintenance personnel when a problem occurs in one or more of the streams. A view of the Raw Data or Analysis Reports can help in isolating or indicating areas that may need maintenance attention.
Page 169: Maintenance
MODEL 1000 SEP 2005 MAINTENANCE This section provides instructions and checklists for maintaining or repairing the Model 1000 GC System. This section is organized as follows: Troubleshooting and Repair Concept ....... . See Section 5.1 Routine Maintenance .
Page 170 MODEL 1000 SEP 2005 GC Controller Maintenance ........See Section 5.6 GC Controller Access .
Page 171: Troubleshooting And Repair Concept
Daniel Measurement Services (DMS), a division of Emerson Process Management, with a problem. Also have the Sales Order number when calling. The Sales Order number can be found on the upper right hand corner of the upper electronics housing of the Analyzer.
Page 172: Gc System Maintenance Checklist
MODEL 1000 SEP 2005 5.2.1 GC System Maintenance Checklist Date Performed ___ /___ / ___ Sales Order No. HE- __________ BI-MONTHLY AS FOUND AS LEFT NOMINAL CARRIER CYLINDER Cylinder Pressure Reading (High) ____ psig ____ psig Cylinder Pressure Outlet Reading ____ psig ____ psig 110 psig...
Page 173: Routine Maintenance Procedures
Contracts for service and repair can be arranged by contacting the Daniel Measurement Services (DMS), a division of Emerson Process Management, at the address or telephone number on the Customer Repair Report at the back of this manual. There are also contact numbers and information available via www.empersonprocess.com/daniel.
Page 174: Locating And Gaining Access To Equipment Elements
MODEL 1000 SEP 2005 LOCATING AND GAINING ACCESS TO EQUIPMENT ELEMENTS 5.3.1 Analyzer Electrical/Electronic Units The electrical/electronic units of the Analyzer, except for the detector and heater elements, are located in the upper enclosure of the Analyzer and are fully accessible from the front of the unit. Printed circuit assemblies are contained inside an explosion-proof housing, accessible by removing a threaded cover plate from the housing front.
Page 175: Detector Elements, Heater Elements, Valves And Columns
MODEL 1000 SEP 2005 The following circuit assemblies are located inside the upper purged enclosure: Temperature controller/valve-driver printed circuit assembly (on the left side of the housing) The preamplifier printed circuit assembly (on the right side of the housing) Decoder control printed circuit assembly, which is reached by unplugging the temperature controller/valve-driver and the preamplifier printed circuit assembly.
Page 176: Precautions For Handling Printed Circuit Assemblies
MODEL 1000 SEP 2005 PRECAUTIONS FOR HANDLING PRINTED CIRCUIT ASSEMBLIES Printed circuit assemblies contain CMOS integrated circuits, which can be damaged if the assemblies are not properly handled. The following precautions must be observed when working with the assemblies: Do not install or remove the Model 1000 Analyzer printed circuit assemblies or the GC Controller printed circuit assemblies while power is applied to the units.
Page 177: Service, Troubleshooting, And Repair Instructions
MODEL 1000 SEP 2005 SERVICE, TROUBLESHOOTING, AND REPAIR INSTRUCTIONS This section contains service, troubleshooting, and repair information for the Analyzer. The information is arranged as appropriate either by major subsystems or by major functions of the instrument. Table 5-1, Alarms and Possible Causes, refers you to more frequent possible causes for the hardware alarms.
Page 178 MODEL 1000 SEP 2005 Analog Output 6 High Same as number 9. Analog Output 7 High Same as number 9. Analog Output 8 High Same as number 9. Analog Output 9 High Same as number 9. Analog Output 10 High Same as number 9.
Page 179: Preamplifier
The temperature control circuitry is not field serviceable. If the board fails, return the board to Daniel Measurement Services (DMS), a division of Emerson Process Management, for repair or replacement. If a replacement temperature board is installed, temperature set points must be re-calibrated.
Page 180 MODEL 1000 SEP 2005 To remove the Decoder Board from the upper purged enclosure, proceed as follows: Disconnect the Analyzer 120VAC power source. Loosen two screws securing the round Analyzer electronics faceplate, and remove the faceplate. Remove the two printed circuit board assemblies. Pull firmly, making sure that the wiring harness does not catch on the top of either card.
Page 181: Instructions For Reinstalling The Decoder Board
MODEL 1000 SEP 2005 5.5.3.3 Instructions for Reinstalling the Decoder Board SERIOUS PERSONAL INJURY OR DEATH POSSIBLE The upper purged enclosure should not be opened when the unit is exposed to an explosive environment. If access to the upper purged enclosure is required, precautions must be taken to ensure that an explosive environment is not present.
Page 182: Analyzer Troubleshooting Guide
The following is a guide for troubleshooting if a problem with sample analysis occurs. Table 5-2 is a Troubleshooting Checklist to obtain data for a problem diagnosis. This data will be useful if it becomes necessary to call the Daniel Measurement Services (DMS), a division of Emerson Process Management, for assistance.
Page 183: Baseline Drift
MODEL 1000 SEP 2005 5.5.4.3 Baseline Drift To ensure that the baseline is not drifting, compare the baseline upsets caused by valve actuations with those of the chromatogram provided with the Operational Parameters Sheet. Ensure that no evidence of component elutions is present when no sample is being injected. If differences exist between the two chromatograms, the problem may be due to one or more of the following: Programming of events...
Page 184 MODEL 1000 SEP 2005 Table 5-2. Analyzer Troubleshooting Checklist AS FOUND AS LEFT NOMINAL ANALYZER ® Leak check with SNOOP from carrier gas bottle to Analyzer regulator. ® Leak check with SNOOP from calibration standard to auto- calibration solenoid. Pre-amp balance voltage (see par. _____ mV _____ mV 0 ±0.5 mV...
Page 185 MODEL 1000 SEP 2005 Table 5-2. Analyzer Troubleshooting Checklist (Continued) AS FOUND AS LEFT NOMINAL ANALYZER POWER SUPPLY TB4: Terminals (+20V) ___ Volts +20.0 ±.5V 24 (common) 25 ( 20 Volts), and ( - 20V) ___ Volts -20.0 ±.5 V 26 (+20 Volts) (+20V) ___ mV AC...
Page 186: Leak-Checking The Analyzer
MODEL 1000 SEP 2005 5.5.4.4 Leak-Checking the Analyzer To perform a field-service leak check of the Analyzer, follow these steps: Plug all Analyzer vents. Make sure the setting of the regulator for the carrier gas cylinder is 115 pounds per square inch, gauge (psig).
Page 187 MODEL 1000 SEP 2005 To perform a factory-level leak check of the Analyzer, follow these steps: The following are steps performed to leak-check the Analyzer at the factory when the Analyzer is quality-checked prior to release. This procedure is more thorough and is designed to isolate specific zones of the Analyzer where a leak may occur.
Page 188 MODEL 1000 SEP 2005 Figure 5-2. Analyzer Components 5-20 MAINTENANCE...
Page 189 MODEL 1000 SEP 2005 Figure 5-3. Analyzer Valve Switches, Upper Purged Enclosure Leak check the carrier gas line first, according to the steps that follow. Purge the Analyzer Valves with carrier gas, as follows: Open the carrier gas bottle valve and slowly increase the carrier gas feed line pressure to 110 pounds per square inch gauge (psig), ±2%, with the dual-stage regulator at the supply bottle.
Page 190 MODEL 1000 SEP 2005 Do not use the "Carrier Pressure Adjust" valve (on the Flow Panel of the Analyzer) to adjust carrier gas line pressure. That valve is factory-set and should not be adjusted. Toggle each Analyzer Valve switch to OFF and ON positions about four to five times (Analyzer Valve switches are in the upper purged enclosure.) Pressurize and check the carrier gas feed line, as follows: Set all Analyzer Valve switches to the ON position.
Page 191 MODEL 1000 SEP 2005 Plug the Sample Vent (labeled "SV") vent line. Pressurize the calibration gas line to 50 psig. Calibration gas line pressure of 50 psig is for leak check and test purposes only. For normal operation, the calibration gas line pressure is maintained at 20-30 psig. Shut the calibration gas bottle valve.
Page 192: Plugged Lines, Columns, Or Valves
MODEL 1000 SEP 2005 (11) Leak test all other sample stream lines by connecting gas to each of the sample streams and repeating steps (9) through (10)(b). (12) Finish the test and set up the Analyzer for normal operation, as follows: Ensure that all Analyzer Valve switches, upper purged enclosure, are set to the AUTO position.
Page 193: Chromatograph Valves
If service is required, the valve can be overhauled using a standard kit of replacement parts available from Daniel Measurement Services (DMS), a division of Emerson Process Management. The following are procedures for overhauling the valve using a Rebuild Kit from Daniel Measurement Services (DMS).
Page 194: Detector Bridge Balance
MODEL 1000 SEP 2005 5.5.6 Detector Bridge Balance The following procedure should be carried out if the Analyzer does not produce a chromatogram. To perform a detector bridge balance, follow these steps: Halt any ongoing analyses. If you are using the MON2000 software program, select the "Control"...
Page 195: Temperature Measurements
MODEL 1000 SEP 2005 5.5.7 Temperature Measurements To measure the Detector and Heater Block temperatures, you will need a FLUKE Model 51 K/J ® thermometer or equivalent. To measure Detector and Heater Block temperatures, proceed as follows: Open the door of the upper purged enclosure. Next, loosen and remove the four two thumb screws that hold the Valve Driver Board.
Page 196 MODEL 1000 SEP 2005 Set the thermometer for a "J" reading, then insert the ends of the two wires marked #1, and measure their temperature. Repeat with wire #2. The column heater temperatures should be 80±3 °C. The detector heater reading will be 5°...
Page 197: Measure Vent Flow (Mv)
MODEL 1000 SEP 2005 5.5.8 Measure Vent Flow (MV) You will need an accurate flow meter (Alltech Digital Flow Check™ Flowmeter or equivalent) for this measurement. To measure the MV vent flow, proceed as follows: Attach a flow meter to the vent output on the left side of the Analyzer marked "MV". The flow should measure 12-18 cc/min.
Page 198 MODEL 1000 SEP 2005 Table 5-4. Analog Inputs to GC Controller (from User Devices) Board Acronyms: Terminal Board for Field Wiring at Controller (TB) TB, J12, Terminals 1,2,3 4-20 mA, common, shield Analog-in 1 TB, J12, Terminals 4,5,6 4-20 mA, common, shield Analog-in 2 TB, J12, Terminals 7,8,9 4-20 mA, common, shield...
Page 199: Gc Controller Maintenance
MODEL 1000 SEP 2005 GC CONTROLLER MAINTENANCE The GC Controller is designed to operate for long periods of time without need for preventive or regularly scheduled maintenance. SERIOUS PERSONAL INJURY OR DEATH POSSIBLE The upper purged enclosure should not be opened when the unit is exposed to an explosive environment.
Page 200 MODEL 1000 SEP 2005 Note the location of any board removed. Remove only one end of any cable necessary to obtain access to the desired board. Remember or make note of the cable installation so the cables can be replaced in the same order. Release the catch(es) and remove/replace the circuit board(s) as necessary.
Page 201: Communications
MODEL 1000 SEP 2005 COMMUNICATIONS See Section 3.4.4, this manual, for a list of the GC Controller ports and terminals (pins) assigned to serial communications. There are 3 to 8 communications ports available from the GC Controller. In addition, a communications port (8) is used by the GC Controller display and keypad.
Page 202: Gc Controller Address Change
MODEL 1000 SEP 2005 5.7.1 GC Controller Address Change See Section 3.4.1, this manual, for an explanation of DIP switch settings and their determination of the GC Controller's Modbus slave address (COM ID). When the desired GC Controller device address is known, it will be set before the Model 1000 leaves the factory.
Page 203: Analog Output Dialog Description
MODEL 1000 SEP 2005 5.8.1 Analog Output Dialog Description Use the Application > Analog Outputs menu path to access this function. The Analog Outputs dialog box appears. To edit the settings displayed, double-click on the appropriate cell or left-click the mouse button and use the provided pull-down menus.
Page 204 MODEL 1000 SEP 2005 Table 5-5. Description of Analog Output Settings Setting Description < Number> number label assigned Number of available analog outputs is dependent upon the GC controller model. Note: If the GC unit includes an Analog Expansion Module (AEM), PN 1-0500-001, reserve analog output number 1 (first row) for the variable Bargraph.
Page 205: Changing A Variable
MODEL 1000 SEP 2005 When defining a new analog output, perform a calibration first to obtain accurate Zero and Full Adjustment values (see Section 5.8.4 or Section 5.8.5). 5.8.2 Changing a Variable To change a variable assignment, click on the appropriate Variable cell. Use the provided pull-down menu and click on the desired variable to select it.
Page 206: Changing The Bargraph
MODEL 1000 SEP 2005 5.8.3 Changing the Bargraph Use this function to designate which AEM output analog signals can be used to drive the bargraph device inputs. Each of the 16 available AEM output signals can be assigned to represent various GC analysis data variables.
Page 207 MODEL 1000 SEP 2005 To change a variable assignment, click on the appropriate Variable cell. Use the provided pull-down menu and click on the desired variable to select it. Click on the OK button to accept your changes and return to the Analog Outputs dialog box. Click on the Cancel button to abort and return to the Analog Outputs dialog box.
Page 208: Performing An Manual Calibration
MODEL 1000 SEP 2005 5.8.4 Performing a Manual Calibration To manually calibrate an analog output: Use the Application > Analog Outputs menu path to access this function. The Analog Outputs dialog box appears. Select the desired analog output by clicking anywhere in the corresponding row. Set the Zero Scale and Full Scale values as desired.
Page 209 MODEL 1000 SEP 2005 Return to the Analog Outputs dialog box. Wait until the Current Value of the analog output is equal to the Zero Scale value (see Step 2). (10) Record the value, in engineering units, read by the receiving device (e.g., a voltmeter). (11) Set Fixed Value equal to the Full Scale value (see Step 2).
Page 210: Performing An Automated Calibration
MODEL 1000 SEP 2005 5.8.5 Performing an Automated Calibration To perform an automated analog output calibration, from the Analog Outputs dialog box: Use the Application > Analog Outputs menu path to access this function. The Analog Outputs dialog box appears. Select the desired analog output by clicking anywhere in the corresponding row.
Page 211 MODEL 1000 SEP 2005 To determine the uncalibrated Zero Scale and Full Scale analog output levels, see Section 5.8.1. The Full Scale Adjustment dialog box appears (“Current device value on engineering units”). Input the appropriate value and click on the OK button. To prevent scale adjustment, set both adjustment values to zero (0.0).
Page 212: Analog Loopback Test Circuits
MODEL 1000 SEP 2005 5.8.6 Analog Loopback Test Circuits External loopback test circuits can be built for troubleshooting the GC System's analog input/output operation. See Figures 5-6 and 5-7. Figure 5-6. Analog Loopback with Two Analog Outputs 5-44 MAINTENANCE...
Page 213 MODEL 1000 SEP 2005 Figure 5-7. Analog Loopback with More Than Two Analog Outputs 5-45 MAINTENANCE...
Page 214: Upgrading Analog Outputs
MODEL 1000 SEP 2005 5.8.7 Upgrading Analog Outputs As an option, the GC Controller can be configured with additional analog outputs (there are two analog outputs on the standard Analog Board, P/N 3-2350-041). For more analog outputs, the existing "Analog" board must be exchanged for one of these optional Analog Boards, allowing a quantity of either six or ten analog outputs (see drawing BE-18044 in the GC Controller drawings addendum, this manual): Analog I/O - 6 analog outputs (P/N 3-2350-039)
Page 215: Discrete (Digital) Inputs And Outputs
MODEL 1000 SEP 2005 DISCRETE (DIGITAL) INPUTS AND OUTPUTS For instructions on connecting digital inputs and outputs to the GC Controller, see Section 3.4.6 and drawing DE-20782, GC Controller drawings addendum, this manual. 5.9.1 Digital Loopback Test Circuit An external loopback test circuit can be built for troubleshooting the GC System's digital input/output operation.
Page 216: Fuse Protection
MODEL 1000 SEP 2005 5.10 FUSE PROTECTION AC power fuse protection for the GC Controller is provided by a single fuse, located on the Controller's Terminal Board for Field Wiring (TB). AC power surge protection is also provided by two Metal Oxide Varistors (MOVs). SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Before attempting to examine or replace the Controller's fuse, disconnect AC power from the Controller.
Page 217: Analyzer-Controller Interconnect
MODEL 1000 SEP 2005 To locate and replace the DC power supply cable fuse, note the following: Fuse Location -mounted in line with the 5 VDC power supply cable (P/N 2-3-2350-069) to System Interface Board (P/N 2-3-2350-005). Fuse Size and Capacity - 3AG, Slo-Blo, 2.5 amperes @ 250 VDC 5.11 ANALYZER-CONTROLLER INTERCONNECT Signals between the Analyzer and GC Controller are conducted on the Analyzer-Controller...
Page 218 MODEL 1000 SEP 2005 Figure 5-10. Analyzer and GC Controller Interconnect Leads 5-50 MAINTENANCE...
Page 219: Function Codes
MODEL 1000 SEP 2005 5.11.1 Function Codes If the Analyzer valves are not being activated during "Continuous Operation" or "Auto Sequence" mode, it may be necessary to determine whether Function Code signals are being transmitted correctly. This section provides a guide to the Function Codes. The four Function Code signals form a binary number which, after interpretation by the Analyzer's decoder board, determines the position of specific chromatograph valves.
Page 220 MODEL 1000 SEP 2005 Table 5-6. Voltage Measurements at Function Code Terminals Function Code Function Code Function Code Function Code Cntllr TB - Terminal No. J19, #1 J19, #2 J19, #3 J19, #4 Analyzer - Terminal No. TB4, #11 TB4, #12 TB4, #13 TB4, #14 VOLTAGE MEASUREMENTS...
Page 221 MODEL 1000 SEP 2005 Table 5-7. Function Code Dictionary in Hexadecimal INPUT (hexadecimal) VALVE = SET (ON) VALVE = RESET (OFF) Analyzer Valve (AV)-4 AV-4 AV-5 AV-5 AV-1 AV-1 AV-2 AV-2 Stream Valve (SV)-1 SV-2, -3, -4, -5 SV-2 SV-1, -3, -4, -5 SV-3 SV-1, -2, -4, -5 SV-4...
Page 222 MODEL 1000 SEP 2005 This page intentionally left blank. 5-54 MAINTENANCE...
Page 223: Recommended Spare Parts
The minimum quantities are the number of spares at facilities with only a few Model 1000 GC Systems. Daniel Measurement Services (DMS), a division of Emerson Process Management, offers service and repair service contracts that make maintaining most spares for the Model 1000 GC System unnecessary.
Page 224: Electrical And Mechanical Assemblies (Analyzer)
MODEL 1000 SEP 2005 6.1.2 Electrical and Mechanical Assemblies (Analyzer) Description Part Number Maximum Minimum Allenair 4-Way solenoid valve 4-5000-369 ASCO 3-Way solenoid valve (Auto Cal) 4-5000-075 ASCO 3-Way solenoid repair kit 4-4000-213 G.C. valve repair kit (6-port valve) 3-9300-108 Carrier gas regulator 4-9500-084 Temperature control thermistor...
Page 225: Gc Controller Spares
MODEL 1000 SEP 2005 GC CONTROLLER SPARES 6.2.1 Printed Circuit Card Assemblies (GC Controller) Description Part Number CPU Board No.2 3-2350-090 Analog I/O board No. 5 3-2350-041 6-channel Analog I/O board No.5 (optional) 3-2350-039 10-channel Analog I/O board No.5 (optional) 3-2350-034 System interface and driver board 3-2350-005...
Page 226: Electrical And Mechanical Components (Gc Controller)
MODEL 1000 SEP 2005 6.2.2 Electrical and Mechanical Components (GC Controller) Description Part Number Maximum Minimum 115/230 VAC power supply 3-2350-020 Fuse, 250 VAC, 2A (5 x 20 mm) 5-4203-420 RECOMMENDED SPARE PARTS...
Page 227 MODEL 1000 SEP 2005 LIST OF APPENDICES Supplemental Wiring Guide - Serial Communications ......Appendix A Manifold for Two Carrier Gas Bottles to GC System ......Appendix B Guide to Transient Protection Modules .
Page 228 MODEL 1000 SEP 2005 This page intentionally left blank. A-ii LIST OF APPENDICES...
Page 229 MODEL 1000 SEP 2005 APPENDIX A SUPPLEMENTAL WIRING GUIDE - SERIAL COMMUNICATIONS This Appendix provides additional information about wiring and interfaces for serial transmissions between the GC System and attached equipment (i.e., a PC, a modem, a Data Collection System (DCS), or a multi-drop serial data highway network).
Page 230: Supplemental Wiring Guide - Serial Communications
MODEL 1000 SEP 2005 GC SERIAL PORT AND CABLE CONFIGURATIONS FOR RS-232 This section provides more detailed information about the serial port connections of the GC Controller. It identifies serial port pin assignments and diagrams for designing RS-232 serial cables, if that is necessary for your application.
Page 231 MODEL 1000 SEP 2005 DB-9 plug connections available for Serial Ports 1, 2, 5, 6, and 7. Four of the serial ports, as noted in Table A-1, permit connection via a DB-9 plug. PC-to-GC connections, direct serial: The GC serial ports were wired to appear as DCE, so a 'straight-through' serial cable is used, instead of a null-modem cable, for a direct serial connection between the GC Controller and the PC.
Page 232: Connection From Gc Controller To Pc
MODEL 1000 SEP 2005 RS-232 CONNECTION FROM GC CONTROLLER TO PC A.2.1 DB-9 Serial Port of GC to DB-9 Port of PC To make an RS-232 serial connection between one of the DB-9 serial ports of the GC, and a PC with DB-9 serial port, you may be able to use a "straight-through"...
Page 233: A.2.2 Db-9 Serial Port Of Gc To Db-25 Port Of Pc
MODEL 1000 SEP 2005 A.2.2 DB-9 Serial Port of GC to DB-25 Port of PC To make an RS-232 serial connection between one of the DB-9 serial ports of the GC, and a PC with DB-25 serial port, you may be able to use a "straight-through" serial cable, terminated as DB-9 male / DB-25 female.
Page 234: A.2.3 Phoenix Plug Port Of Gc To Db-9 Port Of Pc
MODEL 1000 SEP 2005 A.2.3 Phoenix Plug Port of GC to DB-9 Port of PC To make an RS-232 serial connection between one of the Phoenix Plug serial ports of the GC, and a PC with DB-9 serial port, you will need to manufacture the cable and its DB-9, female plug cable end as illustrated below (see Figure A-5).
Page 235: A.2.4 Phoenix Plug Port Of Gc To Db-25 Port Of Pc
MODEL 1000 SEP 2005 A.2.4 Phoenix Plug Port of GC to DB-25 Port of PC To make an RS-232 serial connection between one of the Phoenix Plug serial ports of the GC, and a PC with DB-25 serial port, you will need to manufacture the cable and its DB-25, female plug cable end as illustrated below (see Figure A-6).
Page 236: Connection From Gc Controller To External Modem
MODEL 1000 SEP 2005 RS-232 CONNECTION FROM GC CONTROLLER TO EXTERNAL MODEM A.3.1 DB-9 Serial Port of GC to DB-25 Port of Modem To make an RS-232 serial connection between one of the DB-9 serial ports of the GC, and an external modem with a DB-25 serial port, you will need to manufacture a cable.
Page 237: A.3.2 Phoenix Plug Port Of Gc To Db-25 Port Of Modem
MODEL 1000 SEP 2005 A.3.2 Phoenix Plug Port of GC to DB-25 Port of Modem To make an RS-232 serial connection between one of the Phoenix Plug serial ports of the GC, and an external modem with DB-25 serial port, you will need to manufacture the cable and its DB-25, male plug cable end as illustrated below (see Figure A-8).
Page 238: Example Rs-422 Connection From Pc To Gc
MODEL 1000 SEP 2005 EXAMPLE RS-422 CONNECTION FROM PC TO GC This section demonstrates an example RS-422 connection from a PC to GC that is accomplished through use of an asynchronous line driver / interface device. The line driver device serves as an interface between the RS-232 output of the PC and the RS-422 protocol needed for long distance serial input to the GC.
Page 239 MODEL 1000 SEP 2005 See Section 3.4.4, this manual, for additional details about serial communications setups at the GC Controller. Table A-2. Jumper and Switch Settings for LD485A-MP Line Driver, RS-422 to GC LABEL POSITION PURPOSE Front Panel Switch NORMAL / DLB NORMAL Normal operation used, instead of loopback testing.
Page 240: Example Rs-485 Connection From Pc To Gc
MODEL 1000 SEP 2005 EXAMPLE RS-485 CONNECTION FROM PC TO GC This section demonstrates an example RS-485 connection from a PC to GC that is accomplished through use of an asynchronous line driver / interface device. The line driver device serves as an interface between the RS-232 output of the PC and the RS-485 protocol needed for long distance serial input to the GC.
Page 241 MODEL 1000 SEP 2005 Figure A-10. Example RS-485 Serial Cable Terminations, Line Driver to GC Controller COM3 A-13 SUPPLEMENTAL WIRING GUIDE - SERIAL COMMUNICATIONS...
Page 242 MODEL 1000 SEP 2005 Table A-3. Jumper and Switch Settings for LD485A-MP Line Driver, RS-485 to GC LABEL POSITION PURPOSE Front Panel Switch NORMAL / DLB NORMAL Normal operation used, instead of loopback testing. DIP Switch Banks or Shunts XW 1A DCE / XW1A DCE Sets line driver to operate as XW 1B DTE...
Page 243: Manifold For Two Carrier Gas Bottles To Gc System
MODEL 1000 SEP 2005 APPENDIX B MANIFOLD FOR TWO CARRIER GAS BOTTLES TO GC SYSTEM This Appendix provides a description of the Carrier Manifold that permits connection of two carrier gas bottles, or cylinders, to a Gas Chromatograph (GC) System (part number for the manifold is 3- 5000-050).
Page 244: Illustration
MODEL 1000 SEP 2005 ILLUSTRATION Figure B-1. Manifold for Two Carrier Gas Bottles to GC System MANIFOLD FOR TWO CARRIER GAS BOTTLES TO GC SYSTEM...
Page 245: Installation And Line Purging
MODEL 1000 SEP 2005 INSTALLATION AND LINE PURGING To install and purge the dual-bottle carrier gas manifold, proceed as follows: Install manifold as shown in Figure B-1. Close all valves and tighten all fittings. Run tubing to Analyzer, but do not connect. Back off pressure regulator (counterclockwise) fully.
Page 246: Replacing Carrier Cylinder
MODEL 1000 SEP 2005 (15) Open V-3 and slowly regulate Carrier Cylinder 2 to 100 psig. (By doing this, all but 100 pounds of Carrier Cylinder 1 will be used before any of Carrier Cylinder 2 is used. When Carrier Cylinder 1 gets to 100 pounds, refill the cylinder). Leak-check all of the fittings carefully.
Page 247: Guide To Transient Protection Modules
MODEL 1000 SEP 2005 APPENDIX C GUIDE TO TRANSIENT PROTECTION MODULES This Appendix provides a field service guide to the transient protection modules (TPMs) installed on the Terminal Board for Field Wiring (TB) of the Gas Chromatograph Controller. This Appendix is organized as follows: Purpose of the Transient Protection Modules .
Page 248: Part Applications, Numbers, And Descriptions
TPMs are installed on the rear side of the GC Controller's Terminal Board for Field Wiring (TB). The TB is available from Emerson Process Management in various premanufactured versions with preassigned TPM installations, designed to handle specific combinations of applications. A table that lists the premanufactured TB versions, or configurations, is provided in drawing CE-18118, Sheet 3 (see Addendum 2, GC Controller Drawings, this manual).
Page 249 MODEL 1000 SEP 2005 Table C-1. Transient Protection Modules Installed on the Terminal Board for Field Wiring APPLICATION PART NO. PART DESCRIPTION M # SOCKETS (channel) COM M , RS-232 3-2350-027 Quad Bi-dir Sngl Tnst M 6 (COM 1) M 11 (COM 2) M 4 (COM 3) M 7 (COM 4) COM M , RS-422...
Page 250: Troubleshooting Transient Protection Modules
MODEL 1000 SEP 2005 TROUBLESHOOTING TRANSIENT PROTECTION MODULES To determine the integrity of a transient protection module (TPM), follow the guidelines in these tables (see Tables C-2, C-3, and C-4): Table C-2. Troubleshooting TPM, P/N 3-2350-002 P/N 3-2350-002 16-pin; Quad Sngl Tnst; Controller/Analyzer Interconnect, Stream Switch, and Digital I/O (low current) VISUAL INSPECTION MOVs (M1-M4)
Page 251 MODEL 1000 SEP 2005 Table C-3. Troubleshooting TPM, P/N 3-2350-003 P/N 3-2350-003 20-pin; Quad Diff Tnst; Analog I/O and Digital I/O (low current) VISUAL INSPECTION MOVs (M1-M8) Good Blue in color Failed Discolored to brown or black Resistors (R1-R8) Good Intact Failed Broken, or open...
Page 252 MODEL 1000 SEP 2005 Table C-4. Troubleshooting TPM, P/N 3-2350-019 P/N 3-2350-019 20-pin; Hi Pwr Discrete Output; Digital I/O (high current) VISUAL INSPECTION MOVs (M1-M8) Good Blue in color Failed Discolored to brown or black Resistors (R1-R8) Good Intact Failed Broken, or open EQUIPMENT DAMAGE Remove transient protection module from board before all ohmmeter checks.
Page 253 MODEL 1000 SEP 2005 Table C-5. Troubleshooting TPM, P/N 3-2350-027 P/N 3-2350-027 16-pin; Quad Bi-dir Sngl Tnst; COMM (RS-232, RS-422, RS-485) VISUAL INSPECTION MOVs (M1-M4) Good Blue in color Failed Discolored to brown or black Resistors (R1-R4) Good Intact Failed Broken, or open EQUIPMENT DAMAGE Remove transient protection module from board before all ohmmeter checks.
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Page 255: Internal Modem For Gc Controller
MODEL 1000 SEP 2005 APPENDIX D INTERNAL MODEM FOR GC CONTROLLER This Appendix provides additional information for installing the Internal Modem for the GC Controller. (See drawing BE-20767 in Addendum 2 of this manual). To install the Internal Modem for the GC Controller, follow these steps: Halt any ongoing analysis runs.
Page 256 MODEL 1000 SEP 2005 Lower the Terminal Board down and out of the way, held in place by its ground straps at the bottom of the board. This exposes the Card Cage Assembly. Loosen the four screws that secure the Card Cage Assembly to the chassis. Then remove the Card Cage away from its chassis mount so that it is easy to work on.
Page 257: Setting Solenoid Purge Flows
MODEL 1000 SEP 2005 APPENDIX E SETTING SOLENOID PURGE FLOWS This appendix provides the steps needed to set up solenoid purge flow. Solenoid purge flow is a necessary part of the normal operation of process GC systems that handle multiple streams and are equipped with optional solenoid purge system components.
Page 258 MODEL 1000 SEP 2005 Have on hand the sample system drawing that was included with the GC system as part of the shipping package. This drawing identifies, in schematic form, the location of solenoid purge valves that you will need to operate during this procedure. To set up solenoid purge flow, follow these steps: At the GC Controller, halt continuous analysis.
Page 259 MODEL 1000 SEP 2005 When flows for all streams, except stream 1, are set, manually turn stream 1 OFF at the Analyzer Valve Driver Board. Now, manually turn stream 2 ON at the Analyzer Valve Driver Board. Next, open the solenoid purge valve associated with stream 1 to add 200 ccm to the current flow (as measured at the solenoid purge flow indicator).
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Page 261: 2350 To 2350A Cpu Retrofit Instructions
MODEL 1000 SEP 2005 APPENDIX F 2350 to 2350A CPU RETROFIT INSTRUCTIONS 2350A CPU ASSEMBLY INTRODUCTION The 2350A GC Controller CPU assembly has been designed to include all digital I/O and COM3 and COM4 serial ports. This eliminates the requirement (and additional cost) for an I/O assembly or DSPI/O assembly.
Page 262: Conversion Process
MODEL 1000 SEP 2005 Figure F-1. CPU PC/104 Bus with COM4A Board CONVERSION PROCESS At the GC Controller site, remove the Controller enclosure’s front panel. SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Before removing the unit cover from the GC Controller, make certain the power supply switch is OFF and the AC power cord is disconnected.
Page 263 MODEL 1000 SEP 2005 Locate the GC Controller's Terminal Board for Field Wiring (TB). The TB is attached to the GC Controller's card cage assembly, facing the enclosure's front panel. (In the rack mount Controller, the TB faces outward toward the rear of the enclosure.) Loosen the six screws that secure the TB.
Page 264 MODEL 1000 SEP 2005 (14) Ensure that DIP Switches 6, 7, and 8 of S1 are all in the “OFF” position. If the 2350A is powered up with S8 in the “ON” position, it will delete the current application (commonly called a “Cold Start”).
Page 265 MODEL 1000 SEP 2005 (16) For the purged Controller, the front panel is secured by 16 screws. Remove those screws first. Then carefully lower the front panel on its bottom hinges. The front panel is heavy, so make sure it does not drop and cause damage. The DIP switch is located on the lower left side of the front panel (see Figure F-2).
Page 266 MODEL 1000 SEP 2005 (17) For rack mount and panel mount Controllers, use a flat head screw driver to remove the access panel on the right side of the card cage assembly (see Figure F-3). Figure F-3. Right Side View of Rack Mount and Panel Mount Controllers (18) Inspect or change the DIP switch settings as necessary.
Page 267 MODEL 1000 SEP 2005 Figure F-4. COM ID DIP Switch Switches "1" through "5" form a 5-bit binary number for setting the Modbus slave address (also known as COM ID or Device ID.) Switch number "1" is the least significant bit, and switch number "5" is the most significant bit.
Page 268 MODEL 1000 SEP 2005 Table F-1. Modbus Slave Address (COMID) Dip Switch Settings Switch Positions COM ID RAM CLEAR Dip Switch Setting Switch Positions Clears RAM when unit powered down Keeps RAM when unit powered down 2350 to 2350A CPU RETROFIT INSTRUCTIONS...
Page 269: Basic 2350A Configuration
MODEL 1000 SEP 2005 BASIC 2350A CONFIGURATION At this point, install, if any, all mounting hardware and optional PC/104 boards onto the 2350A CPU Board. Install the 2350A CPU (P/N 3-2350-090) into slot 3 of the card cage assembly. Install cables on the CPU Board in the following sequence: Digital I/O cable (P/N 3-2350-081) from CPU J7 to the System Interface Board J2.
Page 270 MODEL 1000 SEP 2005 Place the “Unit Updated to 2350A” label, included with the upgrade kit, on the instruction decal located on the inside, right wall of the purged units or on the card cage of the rack or panel mount units. Figure F-5a.
Page 271: 2350A Options
MODEL 1000 SEP 2005 2350A OPTIONS The following board configurations are optional for the Model 500 with 2350A Controller. G.4.1 The COM4A Board To add four additional communications ports at the GC Controller site, remove the Controller enclosure's front panel. SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Before removing the unit cover from the GC Controller, make certain the power supply switch is OFF and the AC power cord is disconnected.
Page 272 MODEL 1000 SEP 2005 Loosen the four screws that secure the Card Cage Assembly to the chassis. Then remove the Card Cage Assembly away from its chassis mount so that it is easy to work on. Locate the System Interface and Driver board. It is mounted to the top of the Card Cage Assembly.
Page 273 MODEL 1000 SEP 2005 With COM4A Boards installed, Serial Port 8 is usually assigned via MON2000 Application>Serial Ports menu path. Select Front Panel from the Usage pull- down menu (see Figure F-6a and F-5b below). Figure F-6a. MON2000 Serial Port 8 Front Panel Configuration with COM4A Board Installed Figure F-6b.
Page 274: To Add A Modem
MODEL 1000 SEP 2005 TO ADD A MODEM At the GC Controller site, remove the Controller enclosure's front panel. SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Before removing the unit cover from the GC Controller, make certain the power supply switch is OFF and the AC power cord is disconnected. Observe all safety precautions when you are working in a hazardous environment.
Page 275 MODEL 1000 SEP 2005 Locate the System Interface and Driver board. It is mounted to the top of the Card Cage Assembly. Disconnect the Analog cable from J6 of the System Interface Board, then disconnect all CPU cables from the System Interface Board. Remove the CPU assembly and install the modem with associated hardware into J19 and J20 PC/104 Bus connector on the CPU assembly.
Page 276 MODEL 1000 SEP 2005 To use an existing Modem (1414): For operation with the 2350A CPU, set the Standard 1414 Modem jumpers per the following table: Table F-2. Modem Jumpers Jumper J4/J5 Open 3-5, 4-6 Open ® On the 2350A WinSystems CPU, set J21, pin 13-14. F-16 2350 to 2350A CPU RETROFIT INSTRUCTIONS...
Page 277: To Add An Ethernet Card
MODEL 1000 SEP 2005 TO ADD AN ETHERNET CARD At the GC Controller site, remove the Controller enclosure's front panel. SERIOUS PERSONAL INJURY OR DEATH POSSIBLE Before removing the unit cover from the GC Controller, make certain the power supply switch is OFF and the AC power cord is disconnected.
Page 278 MODEL 1000 SEP 2005 Locate the System Interface and Driver board. It is mounted to the top of the Card Cage Assembly. Disconnect the Analog cable from J6 of the System Interface Board, then disconnect all CPU cables from the System Interface Board. Remove the CPU assembly and install the Ethernet assembly with associated hardware into J19 and J20 PC/104 Bus connector on the CPU assembly.
Page 279 MODEL 1000 SEP 2005 Figure F-9. Ethernet Jumper Configuration BOS v1.84 and Later If an option board is installed on the PC/104 Bus on the CPU, install the Ethernet Board and mounting hardware on the PC/104 Bus connector on the option board. If you are using the CSA approved Radicom modem;...
Page 280 MODEL 1000 SEP 2005 This page intentionally left blank. F-20 2350 to 2350A CPU RETROFIT INSTRUCTIONS...
Page 281 MODEL 1000 SEP 2005 ADDENDUM 1 ANALYZER DRAWINGS This addendum contains schematics and drawings of the Analyzer portion of the Model 1000 Gas Chromatograph System. Drawings are listed below in the same page order as found in this addendum: S.C.S Plate, 1 Stream CE-16120 CE-16180 S.C.S Plate, Single Stream with Model 120 Bypass...
Page 282 MODEL 1000 SEP 2005 This page intentionally left blank. Addendum 1-2 ANALYZER DRAWINGS...
Page 297 MODEL 1000 SEP 2005 ADDENDUM 2 GC CONTROLLER DRAWINGS This addendum contains schematics and drawings of the GC Controller portion of the Model 1000 Gas Chromatograph System. Drawings are listed below in the same page order as found in this addendum: Assembly, Analog Board BE-18044...
Page 298 MODEL 1000 SEP 2005 Block Diagram of GC Controller Circuit Boards Addendum 2-2 GC CONTROLLER DRAWINGS...
Page 315 WARRANTY CLAIM PROCEDURES To make a warranty claim, you, the Purchaser, must: Provide Daniel Measurement Services (DMS), a division of Emerson Process Management, with proof of the Date of Purchase and proof of the Date of Shipment of the product in question.
Page 317 CUSTOMER REPAIR REPORT FOR SERVICE, COM PLETE THIS FORM , AND RETURN IT ALONG W ITH THE AFFECTED EQUIPM ENT TO CUSTOM ER SERVICE AT THE ADDRESS INDICATED BELOW . COM PANY NA M E: TECHNICAL CON TACT: PHONE: REPAIR P. O. #: IF W ARRANTY, UNIT S/N: INVOICE ADDRESS: SHIPPING ADDRESS:...
Page 320 Daniel Measurement and Control, Inc., Daniel Measurement Services, Inc., and Rosemount Analytical, Inc., Divisions of Emerson Process Management reserve the right to make changes to any of its products or services at any time without prior notification in order to improve that product or service and to supply the best product or service possible.

This manual is also suitable for:

Rosemount analytical 1000

Emerson Daniel Danalyzer 1000 Hardware Reference Manual

1 Purpose of this Manual

2 Equipment Description

3 Installation and Setup

4 0 Operation from Local Keyboard and Display

5 Maintenance

6 Recommended Spare Parts

Appendix

100 C Guide to Transient Protection Modules

500 D Internal Modem for Gc Controller

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