Ametek Dycor CG1000-RTP User manual

Dycor CG1000-RTP
User Manual
Thermox
150 Freeport Road
Pittsburgh, PA 15238
PN 90355VE, Rev. N

ii | Dycor CG1000-RTP Oxygen Analyzer
© 2012 AMETEK
This manual is a guide for the use of the Dycor CG1000-RTP. Data herein has been veried and validated and is believed adequate for the intended
use of this instrument. If the instrument or procedures are used for purposes over and above the capabilities specied herein, conrmation of their
validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability. This publication is not
a license to operate under, or a recommendation to infringe upon, and process patents.
USA - HEADQUARTERS
AMETEK Process Instruments
150 Freeport Road
Pittsburgh, PA 15238, USA
Phone: [phone]
Fax: [phone]
USA - Delaware
AMETEK Process Instruments
455 Corporate Boulevard
Newark, Delaware 19702, USA
Phone: [phone] (Main)
800-537-6044 (Service)
800-222-6789 (Ordering)
Fax: [phone]
USA - Texas
AMETEK Process Instruments
9750 Whithorn Drive
Houston, Texas 77095, USA
Phone: [phone]
Fax: [phone]
CANADA
AMETEK Process Instruments
2876 Sunridge Way N.E.
Calgary, Alberta
Canada T1Y 7H9
Phone: [phone]
Fax: [phone]
GERMANY
AMETEK GmbH
Postfach 2165
D-40644 Meerbusch
OR
Rudolf-Diesel Strasse 16
D-40670 Meerbusch
Germany
Phone: [phone]
Fax: [phone]
SINGAPORE
AMETEK Singapore PVT. Ltd.
10 Ang Mo Kio Street 65
#05-12 Techpoint
Singapore 569059
Republic of Singapore
Phone: [phone]
Fax: [phone]
FRANCE
AMETEK - APIF
Rond Point de l’épine des champs
Buroplus Bat D
78990 Elancourt, France
Phone: [phone]
Fax: [phone]
CHINA
AMETEK Process Instruments
Room 408, Metro Tower
No. 30 Tian Yao Qiao Road
Shanghai, 200030
Phone: [phone]
Fax: [phone]
Ofces

| iii
Contents
OFFICES .................................................................................................................ii
European Standards Information....................................................................... x
CHAPTER 1 CG1000-RTP Oxygen Analyzer
Basic Elements of the Sensor............................................................................1-1
The Oxygen Measuring Cell ............................................................................1-2
Hydrocarbons...............................................................................................1-3
Proper Sensor Operations..........................................................................1-4
Technical Support...............................................................................................1-5
CHAPTER 2 Specications
CHAPTER 3 Installation
Mechanical Installation .....................................................................................3-2
PPM Measurement Suggestions......................................................................3-6
Electrical Installation..........................................................................................3-7
Current Output Connections ....................................................................3-7
Alarm Contact Connections ......................................................................3-8
RS-232 Communications Connections.....................................................3-9
Select 115/230 Volt Operation ....................................................................3-9
Start-up and User Interface ............................................................................3-10
System Start-Up .........................................................................................3-11
Password Restrictions ...............................................................................3-11
Auto Ranging Feature ...............................................................................3-11
Keypad Keys...............................................................................................3-12
Selecting Menu Options...........................................................................3-12
Exiting Menu Options ..............................................................................3-12
Automatic Menu Exit Feature..................................................................3-13
On-Line Help .............................................................................................3-13
CHAPTER 4 User Interface
Passwords ............................................................................................................4-1
Setup Key.............................................................................................................4-2
Display...........................................................................................................4-2
Setting Up the Display................................................................................4-3
Set Pressure...................................................................................................4-4
System Tests..................................................................................................4-4
System Serial # ............................................................................................4-5
Primary Calibration....................................................................................4-5
Communication ...........................................................................................4-6
Carrier Gas....................................................................................................4-6
Analog Range Key..............................................................................................4-8
Analog Output Port.....................................................................................4-9
Set Current Range Option .........................................................................4-9

iv | Dycor CG1000-RTP Oxygen Analyzer
Set Track/Hold Option ..............................................................................4-10
Set Current Mode Option ........................................................................4-11
Output Filtering Option...........................................................................4-12
Select Function Option .............................................................................4-12
Alarm Key..........................................................................................................4-13
Overview of Alarm Functions .................................................................4-14
Alarm Set Points.........................................................................................4-14
Alarm Configure........................................................................................4-16
Relay Configure .........................................................................................4-16
Select Function ...........................................................................................4-17
Service Alarm .............................................................................................4-17
Watchdog Relay .........................................................................................4-18
Exception Log.............................................................................................4-18
CHAPTER 5 Calibrate Key
Overview .............................................................................................................5-1
Calibration...........................................................................................................5-2
Calibration vs. Verification Operations....................................................5-2
Span vs. Zero Gas ........................................................................................5-2
Aborting a Calibration ................................................................................5-2
Initiate Cal ...........................................................................................................5-3
Initiate Verify.......................................................................................................5-5
Cal/Verify Data....................................................................................................5-7
Cal Gas Value ......................................................................................................5-9
Configure Verify ...............................................................................................5-10
Set Clock ............................................................................................................5-11
Set Time and Date .....................................................................................5-11
Recovery Duration ....................................................................................5-12
CHAPTER 6 Maintenance And Troubleshooting
System and Error Messages..............................................................................6-1
System Messages................................................................................................6-2
Error Messages....................................................................................................6-3
Diagnostic Checks..............................................................................................6-5
Thermocouple Checks ................................................................................6-5
Calibration Checks ......................................................................................6-6
AC Power Checks.........................................................................................6-7
Furnace Checks............................................................................................6-7
Cell Checks ...................................................................................................6-7
General Troubleshooting...................................................................................6-8
CHAPTER 7 Parts Replacement
Cell Replacement................................................................................................7-2
Furnace Replacement ........................................................................................7-5
Replacing the Transformer ...............................................................................7-8
Replacing the Backplane Board .......................................................................7-9
Replacing Display/Keypad Modules.............................................................7-10

| v
APPENDIX A Serial Communications
Communication Protocol.................................................................................A-1
Command Message Format.............................................................................A-2
General Serial Communication Commands................................................. A-3
Development Serial Communication Commands....................................... A-4
Command List ...................................................................................................A-5
Responses ...........................................................................................................A-6
Variable Table ..................................................................................................... A-7
APPENDIX B Menu Option Charts
Setup Key Menu................................................................................................ B-1
Calibrate Key Menu .......................................................................................... B-2
Alarm Key Menu ............................................................................................... B-2
Analog Range Key Menu ................................................................................. B-3

vi | Dycor CG1000-RTP Oxygen Analyzer
Safety Notes
WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize
critical instructions as follows:
An operating procedure which, if not strictly observed, may result in
personal injury or environmental contamination.
An operating procedure which, if not strictly observed, may result in dam-
age to the equipment.
Important information that should not be overlooked.
Electrical Safety
Up to 5 kV may be present in the analyzer housings. Always shut down power
source(s) before performing maintenance or troubleshooting. Only a qualified
electrician should make electrical connections and ground checks.
Any use of the equipment in a manner not specified by the manufacturer may
impair the safety protection originally provided by the equipment.
Grounding
Instrument grounding is mandatory. Performance specifications and safety
protection are void if instrument is operated from an improperly grounded
power source.
Verify ground continuity of all equipment before applying power.

| vii
PROTECTIVE CONDUCTOR TERMINAL
(BORNIER DE L’ECRAN DE PROTECTION)
Schutzerde
CAUTION - Risk of electric shock
(ATTENTION-RISQUE DE DÉCHARGE ÉLECTRIQUE)
Achtung - Hochspannung Lebensgefahr
CAUTION - (Refer to accompanying documents)
(ATTENTION-SE RÉFERER AUX DOCUMENTS JOINTS)
Achtung (Beachten Sie beiliegende Dokumente)
CAUTION - Hot Surface
(ATTENTION-SURFACE CHAUDE)
Achtung - Heiße Oberäche
Warning Labels
These symbols may appear on the instrument in order to alert you of existing
Environmental Information (WEEE)
This AMETEK product contains materials that can be reclaimed and recycled.
In some cases the product may contain materials known to be hazardous to the
environment or human health. In order to prevent the release of harmful sub-
stances into the environment and to conserve our natural resources, AMETEK
recommends that you arrange to recycle this product when it reaches its “end of
life.”
Waste Electrical and Electronic Equipment (WEEE) should never be disposed of
in a municipal waste system (residential trash). The Wheelie Bin marking on this
product is a reminder to dispose of the product properly after it has completed
its useful life and been removed from service. Metals, plastics and other compo-
nents are recyclable and you can do your part by one of the following these
steps:
• Whentheequipmentisreadytobedisposedof,takeittoyourlocalor
regional waste collection administration for recycling.
• Insomecases,your“end-of-life”productmaybetradedinforcredit
towards the purchase of new AMETEK instruments. Contact your
dealer to see if this program is available in your area.
• IfyouneedfurtherassistanceinrecyclingyourAMETEKproduct,
contact our office listed in the front of the instruction manual.

viii | Dycor CG1000-RTP Oxygen Analyzer
Electromagnetic Compatibility (EMC)
Read and follow the recommendations in this section to avoid performance
variations or damage to the internal circuits of this equipment when installed
in harsh electrical environments.
The various configurations of the CG1000-RTP should not produce, or fall victim to,
electromagnetic disturbances as specified in the European Union’s EMC Directive.
Strict compliance to the EMC Directive requires that certain installation techniques
and wiring practices are used to prevent or minimize erratic behavior of the Ana-
lyzer or its electronic neighbors. Below are examples of the techniques and wiring
practices to be followed.
In meeting the EMC requirements , the various Analyzer configurations described
in this manual rely heavily on the use of metallic shielded cables used to connect to
the customer’s equipment and power. Foil and braid shielded I/O and DC power
cables are recommended for use in otherwise unprotected situations. In addition,
hard conduit, flexible conduit, and armor around non-shielded wiring also provides
excellent control of radio frequency disturbances. However, use of these shielding
techniques is effective only when the shielding element is connected to the equip-
ment chassis/earth ground at both ends of the cable run. This may cause ground loop
problems in some cases. These should be treated on a case-by-case basis. Discon-
necting one shield ground may not provide sufficient protection depending on the
electronic environment. Connecting one shield ground via a 0.1 microfarad ceramic
capacitor is a technique allowing high frequency shield bonding while avoiding
the AC-ground metal connection. In the case of shielded cables the drain wire or
braid connection must be kept short. A two-inch connection distance between the
shield’s end and the nearest grounded chassis point, ground bar or terminal is highly
recommended. An even greater degree of shield performance can be achieved by
using metallic glands for shielded cable entry into metal enclosures. Expose enough
of the braid/foil/drain where it passes through the gland so that the shield materials
can be wrapped backwards onto the cable jacket and captured inside the gland, and
tightened up against the metal interior.
Inductive loads connected to the low voltage “Alarm Contacts” are not recommend-
ed. However, if this becomes a necessity, adhere to proper techniques and wiring
practices. Install an appropriate transient voltage suppression device (low voltage
MOV, “Transzorb,” or R/C) as close as possible to the inductive device to reduce the
generation of transients. Do not run this type of signal wiring along with other I/O or
DC in the same shielded cable. Inductive load wiring must be separated from other
circuits in conduit by using an additional cable shield on the offending cable.
In general, for optimum protection against high frequency transients and other dis-
turbances, do not allow installation of this Analyzer where its unshieled I/O and DC
circuits are physically mixed with AC mains or any other circuit that could induce

| ix
SPECIAL WARNINGS AND INFORMATION
EQUIPMENT USED IN CLASS I, DIVISION 2 HAZARDOUS LOCATIONS
This Equipment is Suitable for Use in Class I, Division 2, Groups ABCD, T4 or Non-Hazardous
Areas Only.
Division 2 stand-alone Analyzer is not supplied with the 24 VDC power sup-
ply option.)
Explosion Hazard - Substitution of Components May Impair Suitability for
Class I, Division 2.
Risque d’explosion - La substitution de composants peut rendre ce ma-
teriel inacceptable pour les emplacements de Classe I, Division 2.
Explosion Hazard - Do Not Disconnect Equipment Unless Power Has Been
Switched Off or the Area is Known to be Non-Hazardous.
Risque d’explosion - Avant de déconnecter l’équipement, coupez le cou-
rant où vous assurez que l’emplacement est designé non dangereux.
All input and output wiring must be in accordance with Class I, Division 2 wiring methods (NEC
Sec 501.4(b) or CEC 18-152) and in accordance with the authority having jurisdiction.
If the CG1000-RTP is to be powered by a source of 24 VDC other than that supplied by AME-
TEK, the power source’s output must be isolated from hazardous mains voltages using double
or reinforced insulation which has a minimum dielectric strength of 2300 VAC. When the
CG1000-RTP is used in a Class I, Division 2 area, this external power source must be located in a
general-purpose area or be Division 2-approved.

x | Dycor CG1000-RTP Oxygen Analyzer
European Standards Information
Manufacturer’s Name:AMETEK Process Instruments (ISO 9001 Regis-
tered 1995)
Manufacturer’s Address:Process & Analytical Instruments Division
150 Freeport Road
Pittsburgh, PA, 15238 USA
Phone: [phone] Fax: [phone]
EU Representative Address: Dr. Jurgen Gassen
AMETEK Precision Instruments Europe GmbH
Rudolf-Diesel-Strasse 16
D-40670 Meerbusch, Germany
Phone: [phone] Fax: [phone]
declares that the product:
Product Name: CG1000-RTP Oxygen Analyzer
complies with the requirements of EMC Directive 89/336/EEC:
EN 50082-2, Immunity (Heavy Industrial) using:
EN 61000-4-2 Electrostatic Discharge
EN 61000-4-4 Electrical Fast Transients
ENV 50140 RF Radiated
ENV 50204 RF Radiated (pulsed)
ENV 50141 RF Induced
EN 61000-4-8 Magnetic
Emissions using:
EN 55011 Radiated, Class B
and with the low voltage directive 73/23/EEC:
EN 61010-1 (IEC 1010-1), Safety Requirement for Electrical Equip-
ment