Emerson Rosemount 470XA User manual

Manual
MS-00809-0100-0470, Rev AA
June2023
Rosemount™ 470XA Gas Chromatograph

Notice
EMERSON (“SELLER”) SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS IN THIS MANUAL OR
OMISSIONS FROM THIS MANUAL. SELLER MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO THIS MANUAL
AND, IN NO EVENT, SHALL SELLER BE LIABLE FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT
LIMITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, ETC.
PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER IDENTIFICATION ONLY AND MAY BE
TRADEMARKS/REGISTERED TRADEMARKS OF THESE COMPANIES.
THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORMATIONAL PURPOSES ONLY AND, WHILE EVERY
EFFORT HAS BEEN MADE TO ENSURE THEIR ACCURACY, THEY ARE NOT TO BE CONSTRUED AS WARRANTIES OR
GUARANTEES, EXPRESSED OR IMPLIED, REGARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE
OR APPLICABILITY. WE RESERVE THE RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR SPECIFICATIONS OF SUCH
PRODUCTS AT ANY TIME.
SELLER DOES NOT ASSUME RESPONSIBILITY FOR THE SELECTION, USE, OR MAINTENANCE OF ANY PRODUCT.
RESPONSIBILITY FOR PROPER SELECTION, USE, AND MAINTENANCE OF ANY SELLER PRODUCT REMAINS SOLELY WITH
THE PURCHASER AND END-USER.
Warranty
1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise
expressly provided herein, Emerson (“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. Goods are warranted for twelve (12) months from the date of initial installation or eighteen
(18) months from the date of shipment by Seller, whichever period expires first. Consumables and Services
are warranted for a period of 90 days from the date of shipment or completion of the Services. Products
purchased by Seller from a third party for resale to Buyer (“Resale Products”) shall carry only the warranty
extended by the original manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond
making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If
Buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty
period, Seller shall, at its option, promptly correct any errors that are found by Seller in the firmware or
Services, or repair or replace F.O.B. point of manufacture that portion of the Goods or firmware found
by Seller to be defective, or refund the purchase price of the defective portion of the Goods/Services. All
replacements or repairs necessitated by inadequate maintenance, normal wear and usage, unsuitable power
sources, unsuitable environmental conditions, accident, misuse, improper installation, modification, repair,
storage or handling, or any other cause not the fault of Seller are not covered by this limited warranty, and
shall be at Buyer's expense. Seller shall not be obligated to pay any costs or charges incurred by Buyer or any
other party except as may be agreed upon in writing in advance by an authorized Seller representative. All
costs of dismantling, reinstallation and freight, and the time and expenses of Seller's personnel for site travel
and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Seller. Goods
repaired and parts replaced during the warranty period shall be in warranty for the remainder of the original
warranty period or ninety (90) days, whichever is longer. This limited warranty is the only warranty made
by Seller and can be amended only in a writing signed by an authorized representative of Seller. Except as
otherwise expressly provided in the Agreement, THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY
KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, OR ANY OTHER
MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. It is understood that corrosion or erosion of
materials is not covered by our guarantee.
2. LIMITATION OF REMEDY AND LIABILITY: SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY
IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY HEREUNDER SHALL BE
LIMITED TO REPAIR, CORRECTION, REPLACEMENT, OR REFUND OF PURCHASE PRICE UNDER THE LIMITED
WARRANTY CLAUSE IN SECTION 1 HEREIN. IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR
CAUSE OF ACTION (WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER
TORT, OR OTHERWISE), SHALL SELLER'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXCEED THE PRICE TO
BUYER OF THE SPECIFIC GOODS MANUFACTURED OR SERVICES PROVIDED BY SELLER GIVING RISE TO THE
CLAIM OR CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY TO BUYER AND/OR
ITS CUSTOMERS EXTEND TO INCLUDE INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES. THE TERM
“CONSEQUENTIAL DAMAGES” SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF ANTICIPATED PROFITS,
LOSS OF USE, LOSS OF REVENUE, AND COST OF CAPITAL.
2

Safety messages
Observe all environmental and personal safety messages described in this document, warning labels on the device,
and your company's operational safety requirements.
WARNING
Safety compliance
The seller does not accept any responsibility for installations of this device 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.
Install and operate all equipment as designed and comply with all safety requirements.
If the device is not operated in a manner recommended by the manufacturer, the overall safety could be
impaired.
WARNING
Supply mains connection
Qualified personnel must connect the device to supply mains in accordance with local and national codes.
WARNING
Explosion
Do not open when energized or when an explosive atmosphere is present.
Keep cover tight while circuits are live.
Use cables or wires suitable for the marked "T" ratings.
Cover joints must be cleaned before replacing the cover.
Ensure that conduit runs have a sealing fitting adjacent to the enclosure.
WARNING
Electric shock
Provide a suitable approved switch and fuse or circuit breaker between the power supply and the gas chromatograph
(GC). Use the switch to disconnect power before performing maintenance on the equipment.
WARNING
Electric shock
Keep cover tight while circuits are alive.
Do not open when energized.
Ensure that conduit runs have a sealing fitting adjacent to the enclosure.
WARNING
Ventilation
Use the device in a well-ventilated area.
If you plan to place the device in a sealed shelter, always vent it to atmosphere with 0.25-in. tubing or larger. This
will prevent the build up of H2 and sample gas.
WARNING
Leak testing
Leak test each gas connection at installation.
3

WARNING
Toxic vapors
Exit ports may discharge dangerous levels of toxic vapors.
Use proper protection equipment and a suitable exhaust device.
WARNING
Burns
To prevent burns, do not touch any of the hot parts. All parts of an analyzer are always hot unless it has been
switched off and allowed to cool down.
Before fitting, removing, or performing any maintenance on the analyzer, make sure that it has been switched off
and allowed to cool for at least two hours.
When handling the analyzer, always use suitable protective gloves.
These precautions are particularly important when working at heights.
If burned, seek medical treatment immediately.
WARNING
Substitution of components may impair suitability for Class I, Division 1 and 2.
WARNING
Safe atmosphere
Only use service connections when the atmosphere is known to be safe.
WARNING
This device is heavy equipment. Two people are required to move the device.
Failure to observe this warning may cause serious injury to personnel.
Observe all proper lifting methods as defined by your site operating procedures.
WARNING
Before converting carrier gas to hydrogen, review your local hazardous area requirements to ensure compliance.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’
equipment. This could be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict
physical access by unauthorized personnel to protect end users' assets. This is true for all systems used within the
facility.
NOTICE
The analyzer electronics and oven assembly, when housed inside a purged enclosure, meet the certifications and
classifications identified in the Specifications section of the Product Data Sheet, which is located on the Emerson
website: emerson.com.
4

Waste disposal
Do not dispose of measuring tools into household waste.
Only for EC countries:
In accordance with European Directive 2012/19/EU for Waste Electrical and
Electronic Equipment and its implementation into national right, measuring
tools that are no longer usable must be collected separately and disposed of
in an environmentally correct manner.
5

6

Contents
Chapter 1 About Rosemount 470XA Gas Chromatographs....................................................................9
1.1 Description................................................................................................................................... 9
1.2 Specifications............................................................................................................................... 9
Chapter 2 Equipment overview...............................................................................................................13
2.1 Exterior....................................................................................................................................... 13
2.2 Interior........................................................................................................................................17
Chapter 3 Installation...............................................................................................................................19
3.1 Site requirements......................................................................................................................19
3.2 Actions upon receiving the gas chromatograph (GC)...........................................................19
3.3 Mounting the gas chromatograph (GC)................................................................................. 22
3.4 Mounting the sample conditioning system........................................................................... 30
3.5 Secure the gas chromatograph (GC) to the mounting bracket...........................................36
3.6 Connect tubing.......................................................................................................................... 37
3.7 Connect to the carrier gas........................................................................................................37
3.8 Connect to actuation gas......................................................................................................... 38
3.9 Connect to the calibration gas.................................................................................................39
3.10 Connect to the sample gas.................................................................................................... 40
3.11 Electrical connections............................................................................................................. 42
3.12 Connecting to Ethernet ports................................................................................................ 45
3.13 Connecting to external devices............................................................................................. 50
3.14 Connecting to power.............................................................................................................. 54
3.15 Starting up and configuring the gas chromatograph (GC)................................................56
Chapter 4 Using the Rosemount 470XA................................................................................................. 65
4.1 Connect a local computer to the Rosemount 470XA............................................................ 65
4.2 Interacting with the local operator interface (LOI)............................................................... 67
4.3 Local operator interface (LOI) screen descriptions...............................................................70
4.4 Common local operator interface (LOI) tasks........................................................................84
4.5 Advanced configuration and operation topics...................................................................... 92
Chapter 5 Preventative maintenance.................................................................................................. 101
5.1 Save diagnostic data............................................................................................................... 101
5.2 Set up auto-calibration in software.......................................................................................101
5.3 Display trend data...................................................................................................................101
5.4 Configure the valve timing.....................................................................................................102
Chapter 6 Replacing the Maintainable Module...................................................................................103
6.1 Remove the Maintainable Module........................................................................................103
6.2 Install a Maintainable Module............................................................................................... 107
Chapter 7 Repairing and maintaining the valves............................................................................... 111
7.1 Required tools for valve maintenance..................................................................................111
7.2 Overhaul a valve......................................................................................................................111
7.3 Replace solenoids....................................................................................................................113
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Chapter 8 Troubleshooting.................................................................................................................... 117
8.1 Alarms.......................................................................................................................................117
8.2 GC won't power up..................................................................................................................127
8.3 Un-normalized total error...................................................................................................... 127
8.4 Replace the central processing unit (CPU)...........................................................................129
8.5 Recover the central processing unit (CPU)...........................................................................131
Chapter 9 Spare parts.............................................................................................................................135
Appendix A Pre-defined Modbus® map files.......................................................................................... 137
Appendix B China RoHS table................................................................................................................... 139
Contents Manual
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1 About Rosemount 470XA Gas
Chromatographs
1.1 Description
The Rosemount 470XA Gas Chromatograph (GC) is part of the XA series of Emerson gas
chromatographs. Designed to simplify natural gas measurement analysis, the Rosemount
470XA provides greater ease of use and increased measurement performance for your C6+
BTU/CV analysis.
Another unique benefit of the Rosemount 470XA is its Maintainable Module technology,
which allows you to easily replace the GC module in the field in approximately two hours,
including warm-up and purge, greatly reducing downtime and overall operating costs.
1.2 Specifications
Table 1-1: Electronics specifications
Specification Description
Power supply 24 Vdc (standard) at the unit
21-30 Vdc (operating range) at the unit
Class 2 and SELV as specified by CEC, C22.1, and NEC, National Fire Protection
Association (NFPA)
NOTICE
Provide the gas chromatograph (GC) with one 5-amp circuit breaker for
protection.
Power consumption at 72 °F (22 °C) 50 Watts (start-up)
20 Watts (steady state)
Table 1-2: Construction specifications
Specification Description
Environmental temperature -4 to +140 °F (-20 to +60 °C)
Enclosure protection rating IP65 and Type 4X
Dimensions
(without sample system or mounts)
18 in. (height) x 15.6 in. (width) x 11 in. (depth)
460 mm (height) x 396 mm (width) x 280 mm (depth)
Mounting options Pipe, wall, or bench
Weight (without sample system or
mounts)
50 lb. (23 kg)
Table 1-3: Performance specifications
Specification Description
Applications 4 minute C6+ standard analysis(1)
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Table 1-3: Performance specifications (continued)
Specification Description
Repeatability Controlled environment
•±0.0125% calorific value
•±0.125 BTU/scf per 1,000 BTU/scf
Uncontrolled environment: -4 to +140 °F (-20 to +60 °C)
•± 0.025% calorific value
•± 0.25 BTU/scf per 1,000 BTU/scf
Metrology approvals(2) Measurement Canada
Calculations International Organization for Standardization (ISO) 6976, American Gas
Association (AGA) 8, Gas Processors Association (GPA) 2172 (using the GPA 2145
physical properties table)
Recommended carrier gas
•Purity
•Moisture content
•Hydrocarbon content
•Supply pressure
•Carrier gas flow
Zero-grade helium at 90 psig (6.2 barg) or hydrogen at 30 psig (2.1 barg)
•99.995% (zero-grade)
•Less than 10 ppm
•Less than 0.5 ppm
•75 psig (5.2 barg) for helium; 30 psig (2 barg) for hydrogen
•20 cc/min for helium, 10 cc/min for hydrogen
Recommended actuation gas
•Moisture content
•Particulate
•Supply pressure
Helium, nitrogen, or clean dry air at 90 psig (6.2 barg)
•Less than 10 ppm
•Less than 2 microns
•90 psig (6.2 barg)
Recommended sample (calibration) gas
input pressure range
20 psig (1.4 barg)
Valves Three 6-port diaphragm analytical valves
Oven Airless iso-thermal
Detector Thermal conductivity detector (TCD)
Streams Up to 3 sample streams and 1 calibration stream
Vibration Meets ASTM-4169 specifications
(1) Custom light process applications available upon request.
(2) For additional approvals and certifications information, see Emerson.com.
Table 1-4: Standard communications
Specification Description
Ethernet Two available connections: one RJ-45 plug-in port and one 4-wire termination.
Both with 10/100 mbps.
Analog input One standard input filtered with transient protection, 4–20 mA that is user
scalable and assignable.
Analog outputs Two isolated outputs, 4–20 mA.
Digital inputs One input that is user assignable, optically isolated, and rated to 30 Vdc at 0.5 A.
Digital output One user-assignable output, Form C and electro-mechanically isolated, 24 Vdc.
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Table 1-4: Standard communications (continued)
Specification Description
Serial ports Two termination blocks, configurable as RS-232 or RS-485.
Table 1-5: Archived data storage capabilities
Type(1) Maximum number of records Remarks
Analysis results 86464 240 days with 4 minute cycle time
Final calibration results 370 1 year of final calibration results
Calibration results 100
Final validation results 370 1 year of final validation results
Validation results 100
Analysis chromatogram 3406 Approximately 9.4 days assuming 4
minute cycle time
Final calibration chromatograms 370 1 year of final calibration
chromatograms(2)
Final validation chromatograms 370 1 year of final validation
chromatograms(2)
Protected chromatograms 100 User-selectable
Hourly averages (up to 250 variables)(3) 250 10.4 days
Daily averages (up to 250 variables)(3) 365 1 year
Weekly averages (up to 250 variables)(3) 58 1 year
Monthly averages (up to 250
variables)(3)
12 1 year
Variable averages (up to 250
variables)(3)
250
Every run (up to 250 variables)(3) 250
Alarm logs 1000
Event logs 1000
(1) Based on four-minute BTU with daily calibration application.
(2) The gas chromatograph (GC) can store final calibration or final validation chromatograms for up to a year,
provided that no more than one calibration or validation is run per day, and the cycle time is less than 15
minutes. If the cycle time exceeds 15 minutes, the oldest final calibration or validation chromatograms are
deleted to make room for newer ones.
(3) You can have a total of up to 250 averages of all types, including hourly, 24 hour, weekly, monthly, variable,
and every run averages.
Table 1-6: Maximum approved gas pressure
Gas stream Maximum approved pressure
Sample/calibration 30 psig (2.1 barg)
Carrier 90 psig (6.2 barg)
Actuation 110 psig (7.6 barg)
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Vent specifications
The flows of the vents are:
•Sample vent: 10 to 50 cc/min of sample gas for approximately 3.5 minutes of the four
minute cycle.
•Measure vent: Continuous flow of less than 20 cc/min of carrier gas and 20 cc of sample
gas per analysis cycle.
•Sample bypass: Continuous flow of 150 to 200 cc/min of sample gas.
Product certifications
For product certifications, see the Rosemount 470XA Gas Chromatograph Quick Start Guide.
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2 Equipment overview
2.1 Exterior
NOTICE
Removing one or more of the tamper-proof screws voids the warranty.
NOTICE
Lower cable entry: This is the most convenient entry point for connecting cables to the
Ethernet port, communications ports, and external device terminals. If not using this entry
for cables, use a certified conduit plug. See Table 2-1.
Table 2-1: Certified conduit plugs
Certification type Additionally supplied certified parts
Canadian Standards Association
(CSA)
M32 to ¾-in. adapter and a ¾-in. sealing plug
ATEX/IECEx M32 plug
Figure 2-1: Front view
A. Upper housing (dome)
B. Lower housing
C. Flow panel
D. Local operator interface (LOI)
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Figure 2-2: Left side view
A. Locking bolt
B. Cable entry
C. Ground lug
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Figure 2-3: Right side view
A. Upper cable entry
B. Port hole
C. Lower cable entry
Figure 2-4: Rear view
A. Mounting bolts
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Figure 2-5: Local operator interface (LOI)
A. Exit/cancel
B. Alphanumerical keypad
C. Enter
D. Full color screen: 480 x 272 pixels
E. Up
F. Right
G. Select/edit
H. Left
I. Down
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2.2 Interior
Figure 2-6: Backplane board
A. ANA: Analyzer board
B. CPU: Central processing unit board
C. J8: Local operator interface (LOI) connector
D. TB10: Analog outputs (two)
E. TB2: Analog input
F. LED: LED light(1)
G. TB8: 24 Vdc power
H. SW1: DHCP switch
I. RJ45: Plug-in Ethernet port
J. TB5: Wired Ethernet port
K. TB9: Communication 2 port
L. TB3: Digital output
M. TB4: Communication 1 port
N. TB1: Digital input
(1) The LED light is always on for illumination purposes only.
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Figure 2-7: Maintainable Module
A. Chromatography columns
Separates the sample gas into its component compounds so that they can be detected
and measured. The gas chromatograph's (GC's) pre-coiled, micro-packed columns
contain active materials that selectively impede the flow of individual component
compounds based on their boiling point, so that components with lower boiling points
take longer to travel through the columns than components with higher boiling points.
The GC uses four chromatograph columns and a single restrictor column.
B. Analytical valves
Manipulate the flow of carrier and sample gases through the columns and the detector.
The analytical valves use diaphragm-actuated pistons to block or release the flow of the
gases between adjacent ports on the valve. The majority of maintenance on the
Maintainable Module involves replacing the diaphragms and cleaning the sealing
surfaces of the analytical valves.
C. Module base plate
Most of the components of the analytical module are mounted to the upper and lower
surface of the module base plate.
D. Thermal conductivity detectors (TCDs)
Not shown:
Heater cap Controls the thermal environment surrounding the analytical components of
the module, which is crucial to ensure reliable and repeatable analysis.
Detector Detects and measures the components of the sample gas after the
components are separated by the columns. A single TCD has two thermistors
that respond to the difference in thermal conductivity between the carrier gas
and the separated components.
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3 Installation
3.1 Site requirements
Consider the following when choosing an installation site for the gas chromatograph (GC):
•This GC is designed to operate at temperatures between
-4 and +140 °F (-20 and +60 °C).
•Install the GC as close as possible to the sample point, but allow for adequate access
for maintenance tasks and adjustments. Also, install the GC in a way that allows easy
access and viewing of the local operator interface (LOI).
•Allow at least 10 in. (254 mm) on the right and left sides of the GC to permit access to
the side portal holes where the field terminations are made.
•Allow a minimum of 10 in. (254 mm) above the top of the dome to facilitate access to
the analytical module.
3.2 Actions upon receiving the gas chromatograph
(GC)
3.2.1 Unpacking
WARNING
This device is heavy equipment. Two people are required to move the device.
Failure to observe this warning may cause serious injury to personnel.
Observe all proper lifting methods as defined by your site operating procedures.
The device weighs 50 lb (23 kg) without the sample system. Carefully open and remove the
device from the packing crate.
Manual Installation
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Figure 3-1: Rosemount 470XA
A. Not a lift point
NOTICE
Equipment damage
Lifting the device by the flow panel may cause damage to the equipment.
3.2.2 Inspect and verify received equipment
Check the equipment against the packing slip to see if the shipment is complete.
Inspect the equipment for damage that may have been incurred during shipment. If any
parts or assemblies appear to have been damaged:
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