Emerson Rosemount Analytical 400A User manual

Rosemount Analytical
MODEL 400A
HYDROCARBON ANALYZER
INSTRUCTION MANUAL
NOTE
THIS MANUAL IS APPLICABLE TO MODEL 400A, CATALOG NUMBER 194106
WITH SERIAL NUMBERS BEGINNING WITH 2000001
748262-K

NOTICE
The information contained in this document is subject to change without notice.
Instruction Manual 748262-K
July 1997
Printed in USA
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
Teflon®is a registered trademark of E.I. duPont de Nemours and Co., Inc.
SNOOP®is a registered trademark of NUPRO Co.

CONTENTS
748262-K Rosemount Analytical July 1997 I
Model 400A Hydrocarbon Analyzer
PREFACE
SAFETY SUMMARY ..........................................................................................P-1
SPECIFICATIONS..............................................................................................P-3
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE....P-5
RETURNING PARTS TO THE FACTORY.........................................................P-5
TRAINING ......................................................................................................P-5
DOCUMENTATION............................................................................................P-5
SECTION 1. INTRODUCTION
1.1 DESCRIPTION.........................................................................................1-1
1.2 ANALYZER MOUNTING OPTIONS.........................................................1-1
1.3 FUEL GAS OPTIONS...............................................................................1-2
1.4 OUTPUT OPTIONS..................................................................................1-3
1.4.1 Isolated Remote Range Change and Identification ....................1-4
1.4.2 Range Trim Option......................................................................1-4
1.5 SAMPLE PUMP OPTION.........................................................................1-4
1.6 GAS SAFETY FEATURES.......................................................................1-4
SECTION 2. INSTALLATION
2.1 UNPACKING............................................................................................2-1
2.2 LOCATION...............................................................................................2-1
2.3 VOLTAGE REQUIREMENTS...................................................................2-1
2.4 FUEL AND AIR REQUIREMENTS...........................................................2-2
2.4.1 Fuel Gas.....................................................................................2-2
2.4.2 Air ......................................................................................2-3
2.5 SAMPLE HANDLING................................................................................2-3
2.6 GAS CONNECTION.................................................................................2-4
2.7 LEAK CHECK...........................................................................................2-6

CONTENTS
ii July 1997 Rosemount Analytical 748262-KModel 400A Hydrocarbon Analyzer
SECTION 2. (CONTINUED)
2.8 ELECTRICAL CONNECTIONS ............................................................... 2-6
2.8.1 Line Power Connections ............................................................ 2-6
2.8.2 Voltage Output Selection and Cable Connections for
Recorder....................................................................... 2-7
2.8.3 Voltage to Current Output Board (optional)................................ 2-7
2.8.4 Auxiliary Contacts....................................................................... 2-7
2.8.5 Remote Range Control and Indication....................................... 2-7
2.8.6 Sample Pump Accessory........................................................... 2-9
SECTION 3. STARTUP AND CALIBRATION
3.1 INITIAL STARTUP AND CALIBRATION.................................................. 3-1
3.1.1 Selection of Calibration Method and Assoicated Standard
Gas(es)......................................................................... 3-4
3.2 CALIBRATION PROCEDURE ................................................................. 3-5
3.3 RANGE SWITCH..................................................................................... 3-7
3.4 RANGE TRIM OPTION............................................................................ 3-8
SECTION 4. OPERATION
4.1 ROUTINE OPERATION........................................................................... 4-1
4.2 RECOMMENDED CALIBRATION FREQUENCY.................................... 4-1
4.3 SHUTDOWN............................................................................................ 4-1
4.4 OBTAINING MAXIMUM SENSITIVITY.................................................... 4-2
SECTION 5. THEORY
5.1 PRINCIPLE OF OPERATION.................................................................. 5-1
5.2 BURNER.................................................................................................. 5-1
5.2.1 Response to Different Hydrocarbons......................................... 5-2
5.3 ANALYZER FLOW SYSTEM................................................................... 5-4
5.4 PREAMPLIFIER BOARD......................................................................... 5-4
5.5 MAIN ELECTRONICS BOARD................................................................ 5-5
5.5.1 Post Amplifier............................................................................. 5-5
5.5.2 Digital Display............................................................................. 5-5
5.5.3 Span ..................................................................................... 5-6
5.5.3.1 Range Trim (Option)................................................... 5-6
5.5.4 Remote Range Control............................................................... 5-6
5.6 HEATER/FAN TEMPERATURE ASSEMBLY.......................................... 5-6

CONTENTS
748262-K Rosemount Analytical July 1997 iii
Model 400A Hydrocarbon Analyzer
SECTION 5. (CONTINUED)
5.7 IGNITION CIRCUIT..................................................................................5-7
5.8 SYSTEM POWER SUPPLIES..................................................................5-7
5.9 FLAME-OUT BOARD...............................................................................5-8
SECTION 6. SERVICE AND TROUBLESHOOTING
6.1 SYSTEM CHECKOUT..............................................................................6-1
6.2 SERVICING FLOW SYSTEM AND BURNER..........................................6-2
6.2.1 Burner Disassembly and Cleaning..............................................6-3
6.2.2 Thermistor...................................................................................6-4
6.2.3 Fuel and Air Restrictors ..............................................................6-4
6.2.4 Sample Capillary.........................................................................6-4
6.3 TROUBLESHOOTING .............................................................................6-4
SECTION 7. REPLACEMENT PARTS
7.1 CIRCUIT BOARD REPLACEMENT POLICY ...........................................7-1
7.2 RECOMMENDED REPLACMENT PARTS LIST......................................7-1
GENERAL PRECAUTIONS FOR HANDLING & STORING HIGH PRESSURE CYLINDERS
WARRANTY
FIELD SERVICE AND REPAIR FACILITIES

CONTENTS
iv July 1997 Rosemount Analytical 748262-KModel 400A Hydrocarbon Analyzer
FIGURES
2-1 Range Input-Output Board....................................................................... 2-8
2-2 Range Control and Output Connections.................................................. 2-10
3-1 Power Switch Location............................................................................. 3-2
3-2 Typical Curves of Downscale Response vs. Time for Various
Hydrocarbons............................................................................... 3-5
3-3 Example 1 Display................................................................................... 3-7
3-4 Example 2 Display................................................................................... 3-8
3-5 Example 3 Display................................................................................... 3-8
3-6 Range Trim Option Schematic................................................................. 3-9
4-1 Typical Curve of Analyzer Response vs. Pressure Setting on Sample
Pressure Regulator....................................................................... 4-2
4-2 Typical Curves of Analyzer Response vs. Pressure Setting on Fuel Pressure
Regulator...................................................................................... 4-3
4-3 Typical Curves of Analyzer Response vs. Pressure Setting on Air
Pressure Regulator....................................................................... 4-3
5-1 Flame Ionization Detection Theory.......................................................... 5-1
5-2 Typical Curves of Downscale Response vs. Time for Various
Hydrocarbons............................................................................... 5-2
TABLES
1-1 Fuel Gas vs. Analyzer Characteristics..................................................... 1-3
2-1 Range Control.......................................................................................... 2-8
3-1 Internal Pressure Regulators Settings..................................................... 3-2
3-2 Range Switch Settings............................................................................. 3-7
5-1 Approximate Effective Carbon Numbers.................................................. 5-3
5-2 Input Sensitivities..................................................................................... 5-5
5-3 Fullscale Sensitivity.................................................................................. 5-6
6-1 Troubleshooting....................................................................................... 6-5

CONTENTS
748262-K Rosemount Analytical July 1997 v
Model 400A Hydrocarbon Analyzer
DRAWINGS (LOCATED IN REAR OF MANUAL)
620424 Schematic Diagram, Preamplier
620429 Schematic Diagram, Main Electronics
620434 Schematic Diagram, Isolated V/I
622883 Flow Diagram, Model 400A
623190 Burner Parts List
624003 Schematic Diagram, Temperature Control Board
654328 Installation Drawing, Model 400A
654905 Schematic Diagram, Relay Board
654910 Schematic Diagram, Relay Board
654913 Assembly Instructions, I/O Board
654998 Assembly Instructions, Relay Board
655354 Pictorial Wiring Diagram, Model 400A
657546 Schematic Diagram, Flame-Out Board

CONTENTS
vi July 1997 Rosemount Analytical 748262-KModel 400A Hydrocarbon Analyzer
NOTES

PREFACE
748262-K Rosemount Analytical July 1997 P-1
Model 400A Hydrocarbon Analyzer
CAUTION: HIGH PRESSURE GAS CYLINDERS
SAFETY SUMMARY
To avoid explosion, loss of life, personal injury and damage to this equipment and
on-site property, all personnel authorized to install, operate and service the Model
400A Hydrocarbon Analyzer should be thoroughly familiar with and strictly follow the
instructions in this manual. Save these instructions.
DANGER is used to indicate the presence of a hazard which will cause severe
personal injury, death, or substantial property damage if the warning is ignored
WARNING is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
NOTE is used to indicate installation, operation, or maintenance information which is
important but not hazard-related.
Do not operate without doors and covers secure. Servicing requires access to
live parts which can cause death or serious injury. Refer servicing to qualified
personnel.
For safety and proper performance this instrument must be connected to a
properly grounded three-wire source of power.
This analyzer requires periodic calibration with known zero and standard gases.
Refer to Sections 2.6, 3.8, 3.9, 3.10 and 3.11. See also General Precautions for
Handling and Storing High Pressure Cylinders, following Section 7.
WARNING: ELECTRICAL SHOCK HAZARD

PREFACE
P-2 July 1997 Rosemount Analytical 748262-KModel 400A Hydrocarbon Analyzer
CAUTION: TOPPLING HAZARD
WARNING: PARTS INTEGRITY
WARNING: POSSIBLE EXPLOSION HAZARD
Do not apply power to analyzer or ignite burner until all leak checks have been
performed and until the environment of the analyzer has been determined to be
non-hazardous. See Section 2.7 for leak check procedure.
This instrument uses a fuel containment hydrogen. The instrument is designed to
protect against the formation of an explosive gas mixture within the enclosure. It
must NOT be operated if the internal ventilation fan is not functioning. Do NOT
operate without factory installed fuel flow restrictor in place.
Check the fuel supply and containment system for leaks, both inside and outside the
analyzer, upon installation, before initial startup, during routine maintenance, or any
time the integrity of the fuel containment system is broken, to assure that the system
is leak-tight. Refer to Leak Check Procedure, Section 2.7, Step 6.
The enclosure is protected by a continuous dilution air purge system, as
recommended in IEC* Publication 79-2 (Third Edition - 1983). Do not operate unit
unless the continuous dilution purge system is properly installed and
functioning. Upon startup or loss of pressurization, purge for fifteen minutes
before restoring power unless the internal atmosphere is known to be
non-explosive.
Tampering or unauthorized substitution of components may adversely affect
safety of this product. Use only factory documented components for repair.
This instrument’s internal pullout chassis is equipped with a safety stop latch
located on the left side of the chassis.
When extracting the chassis, verify that the safety latch is in its proper (counter-
clockwise) orientation.
If access to the rear of the chassis is required, the safety stop may be overridden by
lifting the latch; however, further extraction must be done very carefully to insure the
chassis does not fall out of its enclosure.
If the instrument is located on top of a table or bench near the edge, and the chassis
is extracted, it must be supported to prevent toppling.
Failure to observe these precautions could result in personal injury and/or damage to
the product.