Emerson MicroCEM TS Analysis Enclosure-Rev 2.1, MicroCEM Owner's manual

Emerson MicroCEM TS Analysis Enclosure-Rev 2.1, MicroCEM Owner's manual

R o s e m o u n t t

A n a l l y t t i i c a l l

M i i c r r o C E M

T

S

A n a l l y s i i s E n c l l o s u r r e e

Micro Continuous Emission Monitor

Operation & Maintenance Manual

Revision 2.1, Oct. 13, 03

Part Number 1021021-100

Rosemount Analytical UCEM Continuous Analyzer Transmitter

CONTENTS

Preface

Intended Use Statement …………………………………………………………………………….. 1

Safety Summary ……………………………………………………………………………………… 1

Specifications – Analysis Enclosure: General …………………………………………………….. 4

Specifications – Probe/Sample Handling Enclosure: General ..………………………………… 5

Customer Service, Technical Assistance and Field Service ………..………………………….. 6

Returning Parts to the Factory………………………………………………………………………. 6

Training ………………………………………………………………………………………………... 7

1.

1.1

1.2

1.3

1.3.1

1.3.2

1.3.3

1.3.4

2.

2.1

2.1.1

2.1.2

2.1.3

2.2

2.3

Introduction......................................................................... 1–1

Overview..........................................................................................................................1–1

Time Shared Option.........................................................................................................1–3

Theory of Operation.........................................................................................................1–5

NOx.................................................................................................................................. 1–5

CO ................................................................................................................................... 1–5

O2 .................................................................................................................................... 1–6

SO2.................................................................................................................................. 1–7

Detector Methodologies..................................................... 2–1

Non-Dispersive Infrared (NDIR).......................................................................................2–1

Interference Filter Correlation Method ............................................................................. 2–1

Opto-Pneumatic Method.................................................................................................. 2–2

Overall NDIR Method....................................................................................................... 2–4

Paramagnetic Oxygen Method ........................................................................................2–5

Electrochemical Oxygen Method .....................................................................................2–6

3.

Installation........................................................................... 3–1

3.1

3.2

3.2.1

3.3

3.3.1

3.3.2

3.3.3

3.3.4

Specifications...................................................................................................................3–1

Process and Calibration Gas Connection........................................................................3–5

Gas Conditioning ............................................................................................................. 3–6

Installation........................................................................................................................3–1

Location ........................................................................................................................... 3–1

Limitations........................................................................................................................ 3–1

Mounting Options............................................................................................................. 3–1

Electrical Connections ..................................................................................................... 3–1

3.3.4.1

Circular Connector Assembly Instructions .......................................................................3–2

3.3.4.2

EXT I/O Interface Connector ...........................................................................................3–4

3.3.4.3

SHU #1 / #2 Interface Connector.....................................................................................3–6

3.3.4.4

COM Interface Connector................................................................................................3–1

3.3.4.5

Lan Interface Connector ..................................................................................................3–1

3.3.4.6

CPU I/O Interface Connector...........................................................................................3–1

3.3.4.7

SSU Power Connector, T/S units Only ............................................................................3–2

3.3.4.8

AC Power Connector .......................................................................................................3–2

3.3.5

Analytical Leak Check ..................................................................................................... 3–3

3.3.5.1

Flow Indicator Method .....................................................................................................3–1

3.3.5.2

Manometer Method..........................................................................................................3–1

3.3.5.3

Troubleshooting Leaks ....................................................................................................3–3

4.

Startup and Operation........................................................ 4–1

4.1

4.2

Startup Procedure............................................................................................................4–1

Analyzer Operation .......................................................................................................... 4-1

4.2.1

4.2.2

4.2.4

User Interface

...................................................................................................................4-1

µ

CEM Main Window .........................................................................................................4-2

4.2.3

µ

CEM Menus

............................................................................................................... 4-4

µ

CEM Alarms................................................................................................................... 4-6

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

2

CONTENTS

4.2.5

4.2.6

4.2.7

4.3

4.3.1

4.3.2

4.3.3

Stream Switching Control ...............................................................................................4-10

µ

CEM Settings............................................................................................................... 4-11

µ

CEM Settings-Range ....................................................................................................4-11

µ

CEM Settings-Auto Calibration .....................................................................................4-13

µ

CEM Settings - Auto Calibration Time and Frequency .................................................4-14

µ

CEM Settings-Limits ..................................................................................................4-165 4.3.4

4.3.5

µ

CEM Settings-Calibration Gas....................................................................................4-186

4.3.6

µ

CEM Settings-Maintenance Mode 4-

1818

µ

CEM Login

......................................................................................................................4-8

µ

CEM Login-Current User Indication................................................................................4-9

4.3.7

4.3.8

4.4

4.4.1

4.4.2

4.5

4.6

4.6.1

4.6.2

4.6.3

4.6.4

4.6.5

4.6.6

µ

CEM Settings-Manual Calibration.............................................................................4-1918

µ

CEM Settings-Auto Calibration Dialog .....................................................................4-1519

µ

CEM Administration ....................................................................................................... 4-2

µ

CEM Administration-User Settings .................................................................................4-2

µ

CEM Administration-Auto Logoff ....................................................................................4-3

µ

CEM Factory and User Settings .................................................................................... 4-4 uCEM Data Logs ............................................................................................................. 4-7

Maximum Log File Size

....................................................................................................4-7

Maximum Number of Log Files

.........................................................................................4-7

Log File Name Format

......................................................................................................4-7

Measurement Log File Format

Calibration Log File Format

..............................................................................................4-8

Alarm Log File Format

..........................................................................................4-8

....................................................................................................4-10

4.6.7

Accessing the Real-Time ACSII Data String via Ethernet TCP/IP (DAS) .....................4-101

4.7

µ

CEM Data and Diagnotics with the Pocket PC Web Browser ..........................4-1

4.8

Viewing

µ

CEM Data with a Web Browser........................................................................ 4-1

4.8.1

4.8.2

4.8.3

Real-Time Page................................................................................................................4-1

Emissions Page ................................................................................................................4-3

4.9

4.10

Download Page ................................................................................................................4-6

Viewing

µ

CEM Data with MS Excel ................................................................................. 4-7

Auto Calibration ............................................................................................................... 4-1

5.

Maintenance and Service.................................................... 5-1

5.1

5.2

5.3

5.4

5.5

Overview.......................................................................................................................... 5-1

Converter ......................................................................................................................... 5-3

Ozonator .......................................................................................................................... 5-3

Personality Modules ........................................................................................................ 5-3

Detector Assembly........................................................................................................... 5-5

5.6

Central Processing Unit ................................................................................................... 5-8

5.6.1.1

Features........................................................................................................................... 5-8

5.6.1.2

EMBEDDED ENHANCED BIOS:..................................................................................... 5-9

5.6.2

Analog/Digital I/O Board ...................................................................................................5-9

5.6.2.1

Automatic Calibration..................................................................................................... 5-10

5.6.2.2

Analog Inputs................................................................................................................. 5-10

5.6.2.3

Programmable Input Ranges......................................................................................... 5-11

5.6.2.4

Enhanced Trigger and Sampling Control Signals.......................................................... 5-11

5.6.2.5

Analog Outputs .............................................................................................................. 5-11

5.6.2.6

FIFO and 16-Bit Bus Interface ....................................................................................... 5-11

5.6.2.7

Specifications................................................................................................................. 5-12

5.6.3

PCMCIA Adapter ............................................................................................................5-13

5.6.3.1

Features......................................................................................................................... 5-14

5.6.3.2

SOFTWARE FEATURES: ............................................................................................. 5-14

5.6.4

Modem............................................................................................................................5-14

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3

CONTENTS

5.6.4.1

Features......................................................................................................................... 5-15

5.6.5

Flash Drive........................................................................................................................5-1

5.6.5.1

Specifications................................................................................................................... 5-1

5.6.6

Pocket PC.........................................................................................................................5-1

5.6.7

5.6.8

Wireless LAN Adapter ......................................................................................................5-2

500 Watts Power Supply ..................................................................................................5-3

5.6.8.1

FEATURES...................................................................................................................... 5-3

5.7

Replacement Parts .......................................................................................................... 5-4

5.7.1

5.8

5.9

Replacement Part list........................................................................................................5-4

System Enclosure............................................................................................................ 5-9

6.

6.1

6.2

6.3

6.4

Trouble LED................................................................................................................... 5-10

µ

CEM Software .................................................................... 6-1

µ

CEM User Interface Software ........................................................................................ 6-1

µ

CEM Web Server Software............................................................................................ 6-1

Software Development Management .............................................................................. 6-2

µ

CEM Pocket PC Connection Failure.............................................................................. 6-3

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

4

PREFACE

PREFACE

I

NTENDED

U

SE

S

TATEMENT

The µCEM Continuous Emission Monitoring Gas Analyzer is intended for use as an industrial process measurement device only. It is not intended for use in medical, diagnostic, or life support applications, and no independent agency certifications or approvals are to be implied as covering such applications.

S

AFETY

S

UMMARY

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

.

DANGER: ALL PERSONNEL AUTHORIZED TO INSTALL,

OPERATE AND SERVICE THIS EQUIPMENT

To avoid explosion, loss of life, personal injury and damage to this equipment and on-site property, do not operate or service this instrument before reading and understanding this instruction manual and receiving appropriate training.

Save these instructions.

If this equipment is used in a manner not specified in these instructions, protective systems may be impaired.

WARNING: DEVICE CERTIFICATION(S)

Any addition, substitution, or replacement of components installed on or in this device, must be certified to meet the hazardous area classification that the device was certified to prior to any such component addition, substitution, or replacement. In addition, the installation of such device or devices must meet the requirements specified and defined by the hazardous area classification of the unmodified device. Any modifications to the device not meeting these requirements, will void the product certification(s).

Rosemount Analytical

µCEM

Continuous Analyzer Transmitter

1

PREFACE

DANGER: TOXIC GAS

This device may contain explosive, toxic or unhealthy gas components. Before cleaning or changing parts in the gas paths, purge the gas lines with ambient air or nitrogen.

+

WARNING: ELECTRICAL SHOCK HAZARD

POSSIBLE EXPLOSION HAZARD

Do not open while energized. Do not operate without dome and covers secure.

Installation requires access to live parts which can cause death or serious injury.

WARNING: ELECTRICAL SHOCK HAZARD

For safety and proper performance this instrument must be connected to a properly grounded three-wire source of power.

WARNING: POSSIBLE EXPLOSION HAZARD

Ensure that all gas connections are made as labeled and are leak free. Improper gas connections could result in explosion and death.

WARNING: TOXIC GAS

This unit’s exhaust may contain hydrocarbons and other toxic gases such as carbon monoxide. Carbon monoxide is highly toxic and can cause headache, nausea, loss of consciousness, and death.

Avoid inhalation of the exhaust gases at the exhaust fitting.

Connect exhaust outlet to a safe vent using stainless steel or Teflon line. Check vent line and connections for leakage.

Keep all tube fittings tight to avoid leaks. See Section 3.3.5 for leak test information.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

2

PREFACE

WARNING: PARTS INTEGRITY AND UPGRADES

Tampering with or unauthorized substitution of components may adversely affect the safety of this instrument. Use only factory approved components for repair.

Because of the danger of introducing additional hazards, do not perform any unauthorized modification to this instrument.

Return the instrument to a Rosemount Analytical Service office for service or repair to ensure that safety features are maintained.

CAUTION: PRESSURIZED GAS

This unit requires periodic calibration with a known standard gas. It also may utilize a pressurized carrier gas, such as helium, hydrogen, or nitrogen. See

General Precautions for Handling and Storing High Pressure Gas Cylinders at the rear of this manual.

CAUTION: HEAVY WEIGHT

U

SE TWO PERSONS OR A SUITABLE LIFTING DEVICE TO MOVE OR

CARRY THE INSTRUMENT

.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3

PREFACE

S

PECIFICATIONS

G

ENERAL

SPECIFICATIONS – Analysis Enclosure: GENERAL

Power:

Universal Power Supply 85 – 125 VAC, 50 – 60 Hz, + 10%, 1000 Watts

Maximum at Start Up. 500 Watts Nominal

MicroProcessor:

Intel Celeron processor, 566MHz, 64MB RAM, PC/104 architecture,

Windows NT embedded Platform

Pocket PC:

206MHz, StrongArm processor, 32MB RAM 32 ROM, 240 X 320 pixels LCD,

TFT color, backlit, Wireless LAN optional

Detectors//Number:

NDIR (CO), UV (SO2), Paramagnetic (O2), Electrochemical (O2),

Chemiluminscent (NOx) // Up to three in one analyzer

Mounting:

Wall Mount

Area Classification:

General Purpose / NEMA 4X Fiberglass Enclosure Compliant

Compliance's:

CSA (Pending)

Ambient Temperature Range:

-30

0

to 50

0

Celsius.

Relative Humidity:

5 to 99%

Inputs/Outputs: The complete I/O list with terminal locations is located in section

3.3.4

Digital:

RS-485 Serial Port. (Multi-Drop Network)

RS-232 Serial Port.

LAN, Ethernet 10/100-BaseT

Connectivity Protocols:

HTML (Web Browser) – Status, file transfer Modem / Web browser

TCP/IP, MTTP ASCII String

Microsoft Shared drive

FTP Logs download

TELNET Server

Analog:

Analog Outputs: Qty. 3 Isolated 4-20 mA dc, 500 ohms Max Load (O2, CO or SO2,

NOx)

Analog Inputs: Qty 2 (Typically; MW, Fuel Flow)

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

4

PREFACE

Digital

Outputs:

Following are connected directly to the MicroCEM Probe/Sample Handling Box:

Sample Pump on/off, Drain Pump on/off, Purge on/off, Calibrate on/off

– All are rated

110VAC @ 1amp Dry Contact.

Qty. 6 digital Outputs

-

TTL: 5 VDC Max Current 20 mA

*Optional Time Share option – Dry Contact used for Stream Indicator.

Digital Inputs:

Qty. 3: (Typical Process on/off, Flame Detect, Shutdown or Initiate Cal)

*Optional additional Inputs (Extended I/O)

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

5

PREFACE

Linearity

Zero Drift

Span Drift

Repeatability

Response Time (t

90

)

Instrument Weight:

62 lbs Typical

Size:

24“ X 20“ X 12“ (H W D)

Ranges:

O2: 0 –2 Selectable to 0 –25% (1% increments)

CO: 0 –100ppm Selectable to 1000ppm (1ppm increments)

NOx: 0 – 10ppm Selectable to 1000ppm (1ppm increments)

Sample Temperature:

0 degrees C to 55 degrees C

Sample flow rate:

.5 to 1.5 liters/min

Warm Up Time:

Max 25 minutes @ low ambient temperatures

Paramagnetic

O

2

)

<+/- 1%

< +/- 1% /day

< +/- 1% /day

< +/- 1%

Electro

Chemical O

2

< +/- 1%

< +/- 1% /day

< +/- 1% /day

< +/- 1%

10< +/-t

90

< +/-15 10< +/-t

90

< +/-15

NDIR

CO

< +/- 1%

< +/- 1% /day

< +/- 1% /day

< +/- 1%

15s< +/-t

90

< +/-

30s

Chemiluminescent

NOx

< +/- 1%

(1)

< +/- 1% /day

(1)

< +/- 1% /day

(1)

< +/- 1%/day

(1)

15s< +/-t

90

< +/-30s

Influence of Ambient

Temperature

(-20C to 45C)

-

On Zero

-On Span

< +/-1%

< +/-1%

< +/-1%

< +/-1%

< +/-2%

< +/-2%

< +/-2%

< +/-2%

(1)

0-10ppm NOx range is <+/- 3%.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

6

PREFACE

SPECIFICATIONS – Probe/Sample Handling Enclosure: GENERAL

Power:

Universal Power Supply 85 – 125 VAC, 50 – 60 Hz, + 10%

750 Watts Maximum at Start Up. 500 Watts Nominal

Mounting:

Customer Flange Mount (2 Hole Top) or Wall Mount for High Temp Option

Area Classification:

General Purpose / NEMA 4X Fiberglass Enclosure

Compliance's:

CSA (Pending)

Ambient Range Temperature:

-30

0

to 50

0

Celsius

Relative Hum:

5 to 99%

Instrument Weight:

Size:

95 lbs Typical

24“ X 34“ X 12“ (H W D)

Stack Sample Moisture:

Up to 25% max

Sample Cooler:

Thermo Electric dual pass Chiller. Permeation Tube (-30 degrees C.

Dewpoint. Customer instrument air required @ 5 L/M, -40 degree C dewpoint

Max. Stack Temperature:

Standard 400

0

F.

Optional: 600 F (available with elongated spool option)

High Temp: 1400 F (Off Stack Option)

Stack Pressure:

Sample Flow Rate:

Typical -5 to 15 inches H

2

O

500 to 2500cc/min

Response Time:

Maximum distance between Analysis Enclosure and Sample

Conditioning/Probe Enclosure is 300'. (Response time is 30 seconds/100' w/1/4" tubing)..

Probe Length:

48" length 316 SS Probe with .5 micron sintered filter. Customer to cut to length in field if necessary. Optional 5’ and 6’ probes.

Mounting Flange:

Sample Pump:

Standard 4“ 150# Raised Face. Shipped Equipped with Gasket

316 SS diaphragm type

Instrument Air Requirements:

Instrument grade air required. 15 SCFM @ 60 -100 PSIG (30 seconds 2 times per day) Pressure Regulation by Customer

C

USTOMER

S

ERVICE

, T

ECHNICAL

A

SSISTANCE AND

F

IELD

S

ERVICE

For order administration, replacement parts, application assistance, on-site or factory repair, service or maintenance contract information, contact:

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

R

ETURNING

P

ARTS TO THE

F

ACTORY

Before returning parts, contact the Customer Service Center and request a Returned

Materials Authorization (RMA) number. Please have the following information when you

Rosemount Analytical

µCEM

Continuous Analyzer Transmitter

1

PREFACE call:

Model Number, Serial Number, and Purchase Order Number or Sales Order

Number.

Prior authorization by the factory must be obtained before returned materials will be accepted. Unauthorized returns will be returned to the sender, freight collect.

When returning any product or component that has been exposed to a toxic, corrosive or other hazardous material or used in such a hazardous environment, the user must attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification that the material has been decontaminated, disinfected and/or detoxified.

Return to:

Rosemount Analytical Inc.

1201 North Main St.

Orrville, OH 44667

USA

T

RAINING

A comprehensive Factory Training Program of operator and service classes is available. For a copy of the Current Operator and Service Training Schedule contact the Technical Services Department at:

Rosemount Analytical Inc.

Phone: 1-330-682-9010

C

OMPLIANCES

This product may carry approvals from several certifying agencies. The certification marks appear on the product name-rating plate.

N

OTES

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

2

INTRODUCTION

1. Introduction

1.1 Overview

This manual describes the Rosemount Analytical Micro Continuous Emission

Monitoring (µCEM) gas Analyzer Module.

The µCEM Analyzer Module is designed to continuously determine the concentration of

O2, CO, SO2, and NOx in a flowing gaseous mixture. The concentration is expressed in percent or parts-per-million.

The sampled gas is collected from the stack and prepared by the Probe/Sample

Handling Enclosure for analysis and processing by the Analysis Enclosure. The

ANALYSIS ENCLOSURE is a stand alone, computer-controlled unit, utilizing PC/104 as the system bus. The uCEM is enclosed in rugged NEMA 4X, IP65 type enclosures, for harsh environment. The ANALYSIS ENCLOSURE utilizes convection cooling with no air intake and air vents. The ANALYSIS ENCLOSURE is modular, general purpose and easily expandable. It utilizes industry standard components such as PC/104 boards, and modular signal conditioning modules.

Rosemount Analytical

µCEM

Continuous Analyzer Transmitter

1–1

INTRODUCTION

Figure 1-1. µCEM Micro Continuous Emission Monitoring – Analysis Enclosure

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

1–2

INTRODUCTION

Figure 1-2. µCEM Micro Continuous Emission Monitoring Gas Analyzer with Time

Share option.

1.2 Time Shared Option

Provides the functionality to monitor and process sample gases from two streams on a time-share scheme. This option allows you to connect one uCEM to two Sample

Handling units.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

1–3

FROM uCEM CAL

TO uCEM

SAMPLE

TO SHU1

CAL GAS

TO SHU2

CAL GAS

FROM SHU1

SAMPLE

FROM SHU2

SAMPLE

EXHAUST

Figure 1-3. Time Share option Flow Diagram

TV1

TV2

TV3

TV4

INTRODUCTION

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

1–4

INTRODUCTION

1.3 Theory of Operation

1.3.1 NOx

The NOx analyzer continuously analyzes a flowing gas sample for NOx [nitric oxide

(NO) plus nitrogen dioxide (NO

2

)]. The sum of the concentrations is continuously reported as NOx.

The µCEM NOx Analyzer Module uses the chemiluminecence method of detection.

This technology is based on NO’s reaction with ozone (O

3

) to produce NO

2

and oxygen

(O

2

). Some of the NO

2

molecules produced are in an electronically excited state (NO

2

* where the * refers to the excitation). These revert to the ground state, with emission of photons (essentially, red light). The reactions involved are:

NO

2

+ O

3

NO

2

* + O

2

NO

2

*

NO

2

+ red light

The sample is continuously passed through a heated bed of vitreous carbon, in which

NO

2

is reduced to NO. Any NO initially present in the sample passes through the converter unchanged, and any NO

2

is converted to an approximately equivalent (95%) amount of NO.

The NO is quantitatively converted to NO

2

by gas-phase oxidation with molecular ozone produced within the analyzer from air supplied by an external source. During the reaction, approximately 10% of the NO

2

molecules are elevated to an electronically excited state, followed by immediate decay to the non-excited state, accompanied by emission of photons. These photons are detected by a photomultiplier tube which produces an output proportional to the concentration of NOx in the sample.

To minimize system response time, an internal sample bypass feature provides highvelocity sample flow through the analyzer.

1.3.2 CO

The optical bench can selectively measure multiple components in a compact design by using a unique dual optical bench design. Depending on the application, any two combinations of NDIR channels can be combined on a single chopper motor/dual source assembly.

Other application-dependent options include a wide range of sample cell materials, optical filters and solid state detectors. The NDIR Microflow detector consists of two chambers, measurement and reference with an interconnected path in which an ultra low flow filament sensor is mounted. During operation, a pulsating flow occurs between the two chambers which is dependent upon: sample gas absorption, modulation by the chopper motor and the fill gas of the detector chambers. The gas flow/sensor output is proportional to the measured gas concentration. The optical bench is further enhanced by a novel “Look-through” detector technique. This design allows two detectors to be arranged in series --- enabling two different components to be measured on a single optical bench.

The optical bench contains a unique eddy current drive chopper motor and source assembly. This design incorporates on board “intelligence” to provide continuous “self test” diagnostics.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

1–5

INTRODUCTION

1.3.3 O2

Paramagnetic:

The determination of oxygen is based on the measurement of the magnetic susceptibility of the sample gas. Oxygen is strongly paramagnetic, while other common gases are not. The detector used is compact, has fast response and a wide dynamic range. The long life cell is corrosion resistant, heated and may be easily cleaned. It has rugged self-tensioning suspension and is of welded Non-Glued construction.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

1–6

INTRODUCTION

1.3.4 SO2

The optical bench can selectively measure multiple components in a compact design by using a unique dual optical bench design. Depending on the application, any two combinations of NDIR channels can be combined on a single chopper motor/dual source assembly.

Other application-dependent options include a wide range of sample cell materials, optical filters and solid state detectors. The NDIR Microflow detector consists of two chambers, measurement and reference with an interconnected path in which an ultra low flow filament sensor is mounted during operation, a pulsating flow occurs between the two chambers which is dependent upon: sample gas absorption, modulation by the chopper motor and the fill gas of the detector chambers. The gas flow/sensor output is proportional to the measured gas concentration. The optical bench is further enhanced by a novel “Look-through” detector technique. This design allows two detectors to be arranged in series --- enabling two different components to be measured on a single optical bench. The optical bench contains a unique eddy current drive chopper motor and source assembly. This design incorporates on board “intelligence” to provide continuous “self test” diagnostics.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

1–7

2. Detector Methodologies

The µCEM can employ up to three different measuring methods depending on the configuration chosen. The methods are: NDIR CO/SO2, Paramagnetic O

2

,

Electrochemical O

2

, and chemiluminescent NOx.

2.1 Non-Dispersive Infrared (NDIR)

The non-dispersive infrared method is based on the principle of absorption of infrared radiation by the sample gas being measured. The gas-specific wavelengths of the absorption bands characterize the type of gas while the strength of the absorption gives a measure of the concentration of the gas component being measured.

An optical bench is employed comprising an infrared light source, two analysis cells

(reference and measurement), a chopper wheel to alternate the radiation intensity between the reference and measurement side, and a photometer detector. The detector signal thus alternates between concentration dependent and concentration independent values. The difference between the two is a reliable measure of the concentration of the absorbing gas component.

Depending on the gas being measured and its concentration, one of two different measuring methods may be used as follows:

2.1.1 Interference Filter Correlation Method

With the IFC method the analysis cell is alternately illuminated with filtered infrared concentrated in one of two spectrally separated wavelength ranges. One of these two wavelength bands is chosen to coincide with an absorption band of the sample gas and the other is chosen such that none of the gas constituents expected to be encountered in practice absorbs anywhere within the band.

The spectral transmittance curves of the interference filters used in the µCEM analyzer and the spectral absorption of the gases CO and CO

2

are shown in Figure 2-1 below. It can be seen that the absorption bands of these gases each coincide with the passbands of one of the interference filters. The forth interference filter, used for generating a reference signal, has its passband in a spectral region where none of these gases absorb. Most of the other gases of interest also do not absorb within the passband of this reference filter.

The signal generation is accomplished with a pyroelectrical (solid-state) detector. The detector records the incoming infrared radiation. This radiation is reduced by the absorption of the gas at the corresponding wavelengths. By comparing the measurement and reference wavelength, an alternating voltage signal is produced.

This signal results from the cooling and heating of the pyroelectric detector material.

Rosemount Analytical

µCEM

Continuous Analyzer Transmitter

2–1

DETECTOR METHODOLOGIES

Figure 2-1. Absorption Bands of Sample Gas and Transmittance of Interference Filters

2.1.2 Opto-Pneumatic Method

In the opto-pneumatic method, a thermal radiator generates the infrared radiation which passes through the chopper wheel. This radiation alternately passes through the filter cell and reaches the measuring and reference side of the analysis cell with equal intensity. After passing another filter cell, the radiation reaches the pneumatic detector.

The pneumatic detector compares and evaluates the radiation from the measuring and reference sides of the analysis cell and converts them into voltage signals proportional to their respective intensity.

The pneumatic detector consists of a gas-filled absorption chamber and a compensation chamber which are connected by a flow channel in which a Microflow filament sensor is mounted. This is shown in Figure 2-2 below.

In principle the detector is filled with the infrared active gas to be measured and is only sensitive to this distinct gas with its characteristic absorption spectrum. The absorption chamber is sealed with a window which is transparent for infrared radiation. The window is usually Calcium Fluoride (CaF

2

).

When the infrared radiation passes through the reference side of the analysis cell into the detector, no pre-absorption occurs. Thus, the gas inside the absorption chamber is heated, expands and some of it passes through the flow channel into the compensation chamber.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

2–2

Absorption chamber

Flow channel with

Microflow sensor

CaF

2

Window

DETECTOR METHODOLOGIES

Compensation chamber

Figure 2-2. Opto-Pneumatic Gas Detector

When the infrared radiation passes through the open measurement side of the analysis cell into the detector, a part of it is absorbed depending on the gas concentration. The gas in the absorption chamber is, therefore, heated less than in the case of radiation coming from the reference side. Absorption chamber gas becomes cooler, gas pressure in the absorption chamber is reduced and some gas from the compensation chamber passes through the flow channel into the absorption chamber.

The flow channel geometry is designed in such a way that it hardly impedes the gas flow by restriction. Due to the radiation of the chopper wheel, the different radiation intensities lead to periodically repeated flow pulses within the detector.

The Microflow sensor evaluates these flow pulses and converts them into electrical pulses which are processed into the corresponding analyzer output.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

2–3

DETECTOR METHODOLOGIES

2.1.3 Overall NDIR Method

In the case of dual-channel analyzers, the broadband emission from two infrared sources pass through the chopper wheel. In the case of the Interference Filter

Correlation (IFC) method, the infrared radiation then passes through combinations of interference filters. In the case of the opto-pneumatic method, the infrared radiation passes through an optical filter depending on the application and need for reduction of influences. Then the infrared radiation enters the analysis cells from which it is focused by filter cells onto the corresponding detector. The preamplifier detector output signal is then converted into the analytical results expressed directly in the appropriate physical concentration units such as percent volume, ppm, mg/Nm

3

, etc. This is shown in Figure

2-3 below.

MOTOR

Light source

Chopper blade

Analysis cell measuring side

Analysis cell reference side

Filter cell

Gas detector

Figure 2-3. Overall NDIR Method

Preamplifier

Chopper blade

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

Duplex filter disc

Adapter cell

(high measuring range)

Analysis cell

(undivided)

Filter cell

Preamplifier

Pyroelectric detector

(solid-state detector)

2–4

DETECTOR METHODOLOGIES

2.2 Paramagnetic Oxygen Method

The paramagnetic principle refers to the induction of a weak magnetic field, parallel and proportional to the intensity of a stronger magnetizing field.

The paramagnetic method of determination of oxygen concentration utilizes nitrogen filled quartz spheres arranged at opposite ends of a bar, the center of which is suspended by and free to rotate on a thin platinum wire ribbon in a cell. Nitrogen (N2) is used because it is diamagnetic or repelled by a magnet.

A small mirror that reflects a light beam coming from a light source to a photodetector, is mounted on the platinum ribbon. A strong permanent magnet specifically shaped to produce a strong, highly inhomogeneous magnetic field inside the analysis cell, is mounted outside the wall of the cell.

When oxygen molecules enter the cell, their paramagnetism will cause them to be drawn towards the region of greatest magnetic field strength. The oxygen molecules thus exert different forces on the two suspended nitrogen filled quartz spheres, producing a torque which causes the mirror to rotate away from its equilibrium position.

The rotated mirror deflects the incident light onto the photodetector creating an electrical signal which is amplified and fed back to a coil attached to the bar holding the quartz spheres, forcing the suspended spheres back to the equilibrium position.

The current required to generate the restoring torque to return the quartz bar to its equilibrium position is a direct measure of the O

2

concentration in the sample gas.

The complete paramagnetic analysis cell consists of an analysis chamber, permanent magnet, processing electronics, and a temperature sensor. The temperature sensor is used to control a heat exchanger to warm the measuring gas to about 55

°

C.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

2–5

DETECTOR METHODOLOGIES

2.3 Electrochemical Oxygen Method

The electrochemical method of determining oxygen concentration is based on the galvanic cell principle shown in Figure 2-4 below.

Lead wire (Anode)

Lead wire (Cathode)

Anode (1) (Lead)

O-Ring

Plastic disc (9)

Plastic top (10)

(Black)

(Red)

Spong3 disc (7)

Cathode (2) (Gold film)

Teflon membrane (4)

Figure 2-4. Electrochemical Oxygen Sensor

The electrochemical oxygen sensor incorporates a lead and gold galvanic process with a lead anode (1) and a gold cathode (2), using an acid electrolyte (3).

Oxygen molecules diffuse through a non-porous Teflon membrane (4) into the electrochemical cell and are reduced at the gold cathode. Water is the byproduct of this reaction.

On the anode, lead oxide is formed which is transferred into the electrolyte. The lead anode is continuously regenerated and, therefore, the electrode potential remains unchanged for a long time. The rate of diffusion and corresponding response time (t

90

) of the sensor is dependent on the thickness of the Teflon membrane.

The electric current between the electrodes is proportional to the O

2

concentration in the sample gas being measured. The resultant signal is measured as a voltage across the resistor (6) and thermistor (5), the latter of which is used for temperature compensation. A change in the output voltage (mV) represents oxygen concentration.

NOTE: The electrochemical O

2

cell requires a minimum internal consumption of oxygen. Sample gases with an oxygen concentration of less than 2% could result in a reversible detuning of sensitivity and the output will become unstable. The recommended practice is to purge the cell with conditioned ambient air between periods of measurement. If the oxygen concentration is below 2% for several hours or days, the cell must be regenerated for about one day with ambient air. Temporary flushing with nitrogen (N

2

) for less than one hour (analyzer zeroing) will have no effect on the sensitivity or stability.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

2–6

DETECTOR METHODOLOGIES

(-)

Gold

(+)

Lead

O

2

+ 4 H + 4 e

2 H

2

O 2 Pb + 2 H

2

O

2PbO + 4 H + 4 e

Summary reaction O

2

+ 2 Pb

2 PbO

Figure 2-5 Reaction of Galvanic Cell

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

2–7

INSTALLATION

3. Installation

WARNING: ELECTRICAL SHOCK HAZARD

Installation and servicing of this device requires access to components which may present electrical shock and/or mechanical hazards. Refer installation and servicing to qualified service personnel.

CAUTION: CODE COMPLIANCE

Installation of this device must be made in accordance with all applicable national and/or local codes. See specific references on installation drawing located in the rear of this manual.

3.1 Specifications

Electrical Power

See Specifications in Preface

Power Cable

AC Operation: 16 gauge, minimum.

Gas Lines

For external gas lines, the use of all new tubing throughout is strongly recommended.

The preferred type is new, Teflon or Stainless Steel tubing, sealed at the ends.

Services

AC as well as input and output digital and analog signals connect through the circular connectors located on the bottom of the uCEM enclosures.

Rosemount Analytical

µCEM

Continuous Analyzer Transmitter

3–1

INSTALLATION

Figure 3-1. Dimensional Drawing, Door closed. Shown with Time Share option.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–2

O2 IN

O2 IN

INST

AIR

ATMOS

PRES

TO SAFE

PLACE

ELECTRICAL

CONNECTIONS

AIR

{

ATMOS

PRES

DRAIN

TO SAFE

PLACE

ELECTRICAL

CONNECTIONS

CAL GAS

IN (CUST)

O2 IN

CAL GAS

OUT

INSTALLATION

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–3

INSTALLATION

4" 150 LB

ASA RF

FLANGE

CONNECTION

10

1

2

3

SV1

10

SAMPLE FLOW

TI1

SP1

1/2 NPT MALE

1

7

SLOPE

7

BLOW

BACK

A

SAMPLE

10

EOV1

D

C

B

CALIB

10

11

SLOPE

11

RC1A

IN

6

OUT

10

EC1

SHU

14

DRAIN

6

SET FOR

8-12 PSIG

RV1

10

IN

RC1B

OUT

REMOTE

OPERATION

FROM MCEM

CONTROLLER

10 FI1

ADJUST FOR

3-4 L/MIN

PI1

PR1

10

ADJUST FOR

20-30 PSIG

10

1/4SSBH/

3/8SSR

4

10 1/4SSBH/

3/8SSR

10

3

10

F2

STACK LOCATION

INSTRUMENT AIR

60-125 PSIG

-40°F DEW POINT

1-5 SCFM

CAL GAS

IN

1-2 LITER/MIN

10

10

PPD1

1/4SSBH/

3/8SSR

2

MS1

10

SAMPLE/CAL

TO ANALYZER

1-2 LITER/MIN

ANALYZER LOCATION

DE-ENERGIZED=STREAM 1

ENERGIZED=STREAM 2 uCEM SAMPLE uCEM CAL

SHU 1 CAL GAS

SHU 2 CAL GAS

NO

C

SV1

NC

14

DRAIN

SHU 1 SAMPLE

SHU 2 SAMPLE

NO

C

SV2

NC

14 5

1/4SSBH/

3/8SSR

10 6

1/4SSBH/

3/8SSR

STREAM 1

EXHAUST

NO C

SV3

NC

ATMOS PRESSURE

DRAIN TO SAFE

LOCATION

ATMOS PRESSURE

DRAIN TO SAFE

LOCATION

SSU

ENCLOSURE

HAMMOND

P/N PJ1086L

+24VDC

3A

4" 150 LB

ASA RF

FLANGE

CONNECTION

10

1

2

3

SV1

10

SAMPLE FLOW

TI1

SP1

1/2 NPT MALE

1

7

SLOPE

7

BLOW

BACK

A

SAMPLE

10

EOV1

D

C

B

CALIB

10

11

SLOPE

11

RC1A

IN

6

OUT

10

6

REMOTE

OPERATION

FROM MCEM

CONTROLLER

10 FI1

ADJUST FOR

3-4 L/MIN

PI1

PR1

10

ADJUST FOR

20-30 PSIG

10

1/4SSBH/

3/8SSR

4

10 1/4SSBH/

3/8SSR

10

3

SET FOR

8-12 PSIG

RV1

10

IN

RC1B

OUT

10

F2

INSTRUMENT AIR

60-125 PSIG

-40°F DEW POINT

1-5 SCFM

CAL GAS

IN

1-2 LITER/MIN

10

10

PPD1

1/4SSBH/

3/8SSR

2

MS1

10

SAMPLE/CAL

TO ANALYZER

1-2 LITER/MIN

1/4" O.D. X .035

WALL TUBING

(BY CUSTOMER)

PRS2

CYL2

PRS1

CYL1

X PPM NO

IN NITROGEN

SPAN GAS

8-12 PSIG

20.9% O2

IN NITROGEN

ZERO GAS

8-12 PSIG

1/4 SSBH

B

CAL

1/4 SSBH

A

SAMPLE

1/4 SSBH

C

MANIFOLD

HIGH

SV3

1/4 SSBH

D

LOW

SV2

1/4 SSBH

E

ZERO

SV1

1/4 SSBH

F

1/4 SSBH

G

EXHAUST

PI1

PR1

SET FOR

12 PSIG

BY CUSTOMER

OZ AIR

NO

SET FOR

1.0 LPM ±0.5 LPM

FI

SV4

C

NC

BPR

PI

SET FOR

5 PSIG

OZONE

GENERATOR

J7 uCEM

CONTROL UNIT

J6

PRESSURE

SWITCH

EO2

DETECTOR

OPTIONAL

NDIR

DETECTOR

NOX TO NO

CONVERTER

SPU

DETECTOR

ASSY

REACTION

CHAMBER

SAMPLE

OZONE

EXHAUST

EC1

14

DRAIN

14

DRAIN

1/4" SS BULKHEAD

SHU

14 5

1/4SSBH/

3/8SSR

ATMOS PRESSURE

DRAIN TO SAFE

LOCATION

10 6

1/4SSBH/

3/8SSR

ATMOS PRESSURE

DRAIN TO SAFE

LOCATION

STREAM 2

Figure System Flow Diagram

53-030-06

1/4 VITON TUBING

59

31270

BULKHEAD PLATE

FRICTION

75

100-900-472-04

MANIFOLD AND

2W1.3W-5DR-E2.46

76

2 WAY VALVES

SAMPLE

108 901090

901090

CAL

3W16W-1NR-V2A6

77

3 WAY VALVE

008436

1/8NPT-1/8t

CYL

SV4

IN

A12

FLOW

816533

1/8FPT-1/8t

029753

"T" CRES

904958

10-32w/seal - 1/8 t (barb)

SWAGELOC

SS-ORM2

TRIM VALVE

1/8NPT-1/8t

96

DWYER

RMA-14SSV

FLOW METER

& VALVE

78

816553

1/8FPT-1/8t

638614

GAUGE

93

810156

1/8MPT-1/8t"T"

IN

42715604

NDIR DETECTOR

72

9032-904

128

A34

A6

31412

1/4 VITON

TUBING

901090

904958

10-32w/seal - 1/8 t (barb)

CAL GAS 1

SV1

CAL GAS 2

901090

904958

10-32w/seal - 1/8 t (barb)

901090

904958

10-32w/seal - 1/8 t (barb)

CAL GAS 3

OZONE

AIR

83 029650 1/4 X 1/8 BRASS

82

016432 1/4 X 1/4 BULKHEAD

EXHAUST

10-32 SET

SCREW

CRES

005088

PLUG

SV2

A11

SV3

008436

1/8NPT-1/8t

016429

10-32 SET

SCREW

CRES

112

904017

REGULATOR

905876

1/8MPT

-1/8t"T"

657719

98

A13

029753

"T" CRES

73

128

90003311

PARAMAGNETIC

DETECTOR

A8

902899 (4)

M4 X 16 SCREW

903205

903205

079112

658157

RESTRICTOR

BRASS

99

31414

OUT

FRICTION

634398

FRICTION I/8 TUBE

INSIDE 1/4 TUBE

91

632784

FRICTION

95

A15

656250

CABLE

632784

FRICTION

903348

31414

812922

904956 812922

A7

812902

REDUCER

1/4 TUBING

(634398)

100

659754

PHOTO DIODE

DETECTOR

905277

1/4t "X"

31415

NOTES:

1. ALL TUBING 31413 1/8 DIA. NATURAL

UNLESS OTHERWISE INDICATED.

1/4 TUBING

Figure 3-3 Analysis Enclosure Internal Gas flow diagram

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–4

INSTALLATION

Analysis Enclosure Critical settings and control:

1. Set MicroCEM Pressure guage (P1)to 5 psig +/- 0.5psig. Pressure set by BPR located behind gauge in detector section. If CO and NOx response times are sluggish this pressure can be increased.

2. Set Calibration gas cylinder dual stage pressure regulators to 10 to 20 psig.

3. Set Flowmeter (F1) to 500cc to 1500cc per min.

4. TV1 is used to balance the flow between a probe and local calibration. It is located beside the solenoid valve manifold.

5. Set Ozone air pressure to 12 psig.

6. Exhaust line should be free of any backpressure. Immediately vent into ½” pipe.

7. Time Share Box:

TV1: Use to equalize cal gas flow between SHU1 and SHU2.

TV2: Use to equalize cal gas flow between SHU1 and SHU2.

TV3: Use to equalize sample flow between SHU1 and SHU2.

TV4: Use to equalize sample flow between SHU1 and SHU2.

8. Pressure Switch: The pressure switch is located beside the pressure gauge. If the sample or cal gas pressure flow below 2.5 psig the MicroCEM will give trouble alarm. The alarm will turn off upon pressure above 4 psig.

3.2 Process and Calibration Gas Connection

Besides sample gas, the µCEM requires other gases for operation. In most cases, one or more Calibration Standards must be provided. These should be cylinders of gas which closely resemble the expected sample, both in species and concentrations.

These calibration gases are normally introduced into the system as an input to the

Sample Conditioning Plate Option or sample conditioning may be provided by others.

Each gas cylinder should be equipped with a clean, hydrocarbon free two-stage regulator with indicating gauges of approximately 0 to 3000 psig (0 to 20.7 Mpa) for cylinder pressure and 0 to 100 psig (0 to 689 Kpa) for delivery pressure. Regulators should have a metallic as opposed to elastomeric diaphragm, and provide for ¼ inch compression fitting outlet and should be LOX clean.

NOTE: All connections specified in the Installation Drawing, in conjunction with the Application Data Sheet, should be made.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–5

INSTALLATION

Figure 3-5. Gas Connections

1 – Sample Gas Inlet (From

Probe)

2 – Calibration Gas

(From Probe)

3 – Gas 3 Inlet (Cal

Gas)

4 – Gas 2 Inlet (Cal Gas)

5 – Gas 1 Inlet (Cal Gas) 6 – Ozone/Air Inlet

(By Cust)

7 – Vent (To Cust vent)

3.2.1 Gas Conditioning

All gases must be supplied to the analyzer as conditioned gases! When the system is used with corrosive gases, it must be verified that there are no gas components which may damage the gas path components.

The gas conditioning must meet the following conditions:

Free of condensable constituents

Free of dust above 2

µ m

Free of aggressive constituents which may damage the gas paths

Temperature and pressure in accordance with the specifications

When analyzing vapors, the dewpoint of the sample gas must be at least 10

°

C below the ambient temperature in order to avoid the precipitation of condensate in the gas paths.

An optional barometric pressure compensation feature can be supplied for the µCEM.

This requires a pressure sensor with a range of 800 – 1,100 hPa. The concentration

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–6

INSTALLATION values computer by the detectors will then be corrected to eliminate erroneous measurements due to changes in barometric pressure.

The gas flow rate must be in the range of 0.5 l/min to a maximum of 1.5 l/min. A constant flow rate of 1 l/min is recommended. NOTE: The maximum gas flow rate for paramagnetic oxygen detectors is 1.0 l/min!

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–7

INSTALLATION

3.3 Installation

WARNING: ELECTRICAL SHOCK HAZARD

Care should be taken if hazardous gases are to be measured or used for calibration.

Refer to installation drawing supplied with the application data package.

3.3.1 Location

The µCEM is designed to be installed in an outdoor environmental location. It is highly recommended that the analyzer be located out of direct sunlight and direct rain/snow to the extent possible to assure longevity and accuracies.

The µCEM analysis enclosure should be installed as near as possible to the probe/sample handling enclosure, in order to avoid low response time caused by long sample gas lines.

The enclosure must be grounded to earth by the user or ground loops and computer lockups are possible.

3.3.2 Limitations

Ambient Temperature: -30

°

to 50

°

Celsius (-34

°

to 122

°

F)

Relative Humidity: 5% to 99%

3.3.3 Mounting Options

Although the µCEM is enclosed in an environmentally sealed enclosure, it should be protected from direct sunlight. In areas subjected to harsh winter climates, protection should be provided from sun, rain and snow. A corrigated awning or other suitable means can be provided to meet these conditions.

3.3.4 Electrical Connections

NOTE: The enclosure is a NEMA 4x. All entry locations must be sealed.

Connect all required signal cables to the connections at the bottom of the µCEM. The cable locations are indicated on the inside bottom cover of the µCEM box. The actual electrical connections will be specified in the Application Data package. All connections are not necessary for every application.

Cable length for these signals should not exceed 3,000 feet (914 meters), to avoid excessive capacitance and corresponding signal distortion.

All connections are made through the bottom of the µCEM enclosure using circular connectors. Mating circular external connectors are provided by Rosemount with a 6’ wire harness pigtail for connections to J1, J3, J5, J6, J7 & J8.

Rosemount Analytical

µCEM

Continuous Analyzer Transmitter

3–1

INSTALLATION

J8

SSU

J7

SHU 2

J6

SHU 1

J5

EXT I/O

J4

LAN

J3

COM

J2

CPU I/O

J1

AC POWER

INPUT

Figure 3-6 Electrical Connections

J1 – AC Power Input

J3 – COM Interface (pocket pc)

J5 – EXT I/O Interface

J2 – CPU I/O

J4 – Ethernet LAN Port

J6 – SHU #1 Interface

J7 – SHU #2 Interface (T/S units only) J8 – SSU Power (T/S units only)

3.3.4.1 Circular Connector Assembly Instructions

Refer to Figure 3-7 for instructions.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–2

INSTALLATION

Figure 3-7. Circular Connector Assembly Instructions

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–3

INSTALLATION

3.3.4.2 EXT I/O Interface Connector (J5) - MicroCEM inputs and outputs are specific for customer use.

The Analog Interface connector has a shell size of 22, 100 contacts. Each pin will accept a wire size of 26, 24, or 22 AWG. Connector and 6’ pigtail by Rosemount.

Pin# NAME DESCRIPTION

1 O2CL+

O2 Stream#1 Reading, 4-20 mA Output

2 O2CL-

COLOR AWG NOTES

Analog Output /

BLK 22

Twisted Pair wire

3 COCL+

CO Stream#1 Reading, 4-20 mA Output

4 COCL- BRN 22

Analog Output /

Twisted Pair wire

22

Analog Output /

RED 22

Twisted Pair wire

ORG 22

Pair wire

YEL 22

Pair wire

11 FLAME1

Stream#1, Optically Isolated Input (Dry

GRN 22

Pair wire (Cust

15 O2CL2+

O2 Stream#2 Reading, 4-20 mA Output

16 O2CL2-

17

CO Stream#2 Reading, 4-20 mA Output

18 COCL2-

BLU 22

Pair wire

WHT 22

Analog Output /

VIO 22

Twisted Pair wire

GRY 22

Analog Output /

Twisted Pair wire

BLK 22

Analog Output /

BRN 22

Twisted Pair wire

29 TRBLNO

Rating

30 TRBLC

31 TRBLNC

RED 22

Pair wire

ORG 22

Pair wire

YEL 22

Pair wire

GRN 22

Pair wire

BLK 22

Digital Output /

Twisted Pair wire

BLU 22

BLK 22

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–4

94 Spare

INSTALLATION

VIO 22

BLK 22

Digital Input / Twisted

GRY 22

Pair wire

RED 22

Twisted Pair wire

ORG 22

Twisted Pair wire

YEL 22

Twisted Pair wire

GRN 22

Twisted Pair wire

BLU 22

Twisted Pair wire

44 NOxOL+

Maintenance (0V = normal, 5V = alarm

Isolated Output, Drty contact (open =

74 BAROP+

75 BAROP-

98 Spare

100 Spare

VIO 22

Twisted Pair wire

BRN 22

Digital Output /

GRY 22

Twisted Pair wire

RED 22

YEL 22

Not Used

Spare

ORG 22

RED 22

Digital Input / Twisted

GRN 22

Pair wire

Table 3-1. EXT I/O Terminal Assignments

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–5

INSTALLATION

3.3.4.3 SHU #1 / #2 Interface Connector (J6 & J7). These wires are to be connected directly to the MicroCEM sample handling enclosure (SHU) and will control the operation of the sample pump, drain pump, purge valve and calibration valve respetively.

All toggle switches in sample handling enclosure should be set to “remote” mode upon hookup of wire so the MicroCEM analysis enclosure will control the full system.

The Digital Interface connector has a shell size of 14, 15 contacts. Each pin will accept a wire size of 20 AWG. Connector and 6’ pigtail by Rosemount.

PIN NAME DESCRIPTION COLOR Handling

Enc. Termination

1 SPUMP1/2NO

Sample Pump #1/2 Control,

2 SPUMP1/2C

Dry contact, 110V 1A

3 SPUMP1/2NC RED 8

4 DPUMP1/2NO

5 DPUMP1/2C

Drain Pump #1/2 Control,

Dry contact, 110V 1A

6 DPUMP1/2NC

7 PURG1/2NO

8 PURG1/2C

Purge Valve #1/2 Control,

Dry contact, 110V 1A

9 PURG1/2NC

GRN 3

10 CAL1/2NO

11 CAL1/2C

Calibration Valve #1/2

Control, Dry contact,

110V 1A

12 CAL1/2NC WHT/BRN Not Used

Internal Jumper terminals 2 and 9 set by Rosemount

Table 3-2. Sample Handling Unit Terminal Assignments

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–6

INSTALLATION

3.3.4.4 COM Interface Connector (J3) – Pocket PC external connection

The COM Interface connector has a shell size of 10, 13 contacts. Each pin will accept a wire size of 28, 26, or 24 AWG. Connector and 3’ pigtail by Rosemount.

SIGNAL NAME DEFINITION

DCD (pin 1)

Data Carrier Detect Input, RS232

DSR (pin 6)

Data Set Ready Input, RS232

RxD (pin 2)

Receive Data Input, RS232

RTS (pin 7)

Request to Send Output, RS232

TxD (pin 3)

Transmit Data Output, RS232

CTS (pin 8)

Clear To Send Input, RS232

DTR (pin 4)

Data Terminal Ready Output, RS232

RI (pin 9)

Ring Indicator Input, RS232

GND (pin 5) Signal Ground, RS232

TxD/RxD+ (pin 2) RS-485 Bidirectional Data

TxD/RxD- (pin 7) RS-485 Bidirectional Data

GND (pin 3)

Signal Ground

VCC

+5V DC

4

5

6

7

PIN

1

2

3

8

9

10

11

12

13

Table 3-3. COM Interface Terminal Assignments

3.3.4.5 Lan Interface Connector (J4) – Customer PC, network or laptop connection

The Lan Interface connector has a shell size of 8, 6 contacts. Each pin will accept a wire size of 28, 26, 24, or 22 AWG.

DEFINITION SIGNAL NAME

TxD+ (pin 1)

TxD- (pin 2)

RxD+ (pin 3)

RxD- (Pin 6)

Transmit Data

Receive Data

Not Used

PIN

1

2

3

4

5-6

Table 3-4. LAN Interface Terminal Assignments

3.3.4.6 CPU I/O Interface Connector (J2) – Rosemount Factory trained port for communication with CPU hard drive

The CPU I/O Interface connector has a shell size of 14, 19 contacts. Each pin will accept a wire size of 28, 26, or 24 AWG.

PIN NAME DESCRIPTION

A RED

B GND

C GREEN GREEN

D GND GREEN

E BLUE BLUE

F GND

G HSYNC GREY

H GND

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µCEM

Continuous Analyzer Transmitter

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INSTALLATION

J VSYNC BLACK

K GND BLACK

L DATA

M CLK

N KBDATA KEYBOARD

R GND

S VCC

R GND

S VCC

GROUND

GROUND

T MSDATA

U MSCLK MOUSE

Table 3-5. CPU I/O Terminal Assignments

3.3.4.7 SSU Power Connector, T/S units Only (J8) – T/S enclosure can be located away from the Analysis enclosure. This cable serves as the connection and is by Rosemount.

The SSU Power connector has a shell size of 8, 3 contacts. Each pin will accept a wire size of

24, 22, or 20 AWG. Connector and 6’ pigtail by Rosemount.

SIGNAL NAME

SSUCtrl

Vbb_rtn

Gnd

DEFINITION

SSU Control line

+24V Return

GND

PIN

A

B

C

Table 3-6. SSU Power Connection Terminal Assignments

3.3.4.8 AC Power Connector (J1) – Customer 120VAC Power Connection

The AC Power Interface connector has a shell size of 12, 3 contacts. Each pin will accept a wire size of 16 AWG. Connector and 6’ pigtail by Rosemount.

SIGNAL NAME DEFINITION PIN

L2 C

B

Table 3-7. AC Power Connection Terminal Assignments

Connect AC power through a 20A circuit breaker that is to be located close to the

µCEM. The circuit breaker will provide over current protection as well as a means of disconnecting the power.

Maximum power requirements will be 1000 watts, with most applications requiring less than this amount

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–2

INSTALLATION

Figure 3-4. uCEM Analysis Enclosure interconnect diagram

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–3

INSTALLATION

3.3.5 Analytical Leak Check

If explosive or hazardous gas samples are being measured with the µCEM, it is recommended that gas line fittings and components be thoroughly leak-checked prior to initial application of electrical power, and at bimonthly intervals thereafter, as well as after any maintenance which involves breaking the integrity of the sample containment system.

3.3.5.1 Flow Indicator Method

Figure 3-8. Leak Test Flow Method

Supply air or inert gas such as nitrogen, at 10 psig (689 hPa), to the analyzer through a flow indicator with a range of 0 to 250 cc/min. Install a shut-off valve at the sample gas outlet. Set the flow rate to 125 cc/min.

Close the outlet shut-off valve and notice that the flow reading drops to zero. If the flow reading does not drop to zero, the system is leaking and must be corrected before the introduction of any flammable sample gas or application of power.

Install a water-filled U-tube manometer at the sample gas outlet. Install a shut-off valve at the sample gas inlet. Admit air or inert gas to the inlet shut-off valve until the analyzer is pressurized to approximately 50 hPa. The water column will be about 500 mm.

N

2

10 psig

(69 kPa)

Flow

Meter

Rosemount Analytical

µCEM

Continuous Analyzer Transmitter

Gas

Outlet

3–1

UCEM Analyzer

Inlet Outlet

INSTALLATION

Overpressure approx. 50

N

2

Water

Figure 3-9. Leak Test Manometer Method

Close the inlet shut-off valve and, following a brief period for pressure equilibrium, verify that the height of the water column does not drop over a period of about 5 minutes. If the water column height drops, the system is leaking and must be corrected before the introduction of any flammable sample gas or application of power.

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

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INSTALLATION

Liberally cover all fittings, seals, and other possible sources of leakage with a suitable leak test liquid such as SNOOP

(part 837801). Bubbling or foaming indicates leakage. Checking for bubbles will locate most leaks but could miss some, as some areas are inaccessible to the application of SNOOP. For positive assurance that system is leak free, perform one of the preceding tests.

NOTE:

Refer to Specification in Preface for maximum pressure limitations.

For differential measurement, the leak check must be performed for the measurement and reference side separately.

For analyzers with parallel gas paths, the leak check must be performed for each gas path separately.

Figure illustrates MicroCEM analysis enclosure (Left) wire connections to the Sample Handling box

Trademark of NUPRO Company

Rosemount Analytical µCEM

Continuous Analyzer Transmitter

3–3

INSTALLATION

4. Startup and Operation

4.1 Startup Procedure

Once the µCEM has been correctly assembled and installed in accordance with the instructions in Section 1.1, “

Rosemount Analytical

µCEM

Continuous Analyzer Transmitter

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STARTUP and OPERATION

Installation,” the analyzer is ready for operation.

Before operating the system, verify that the Leak Checks have been performed and that the sample handling unit is performing correctly.

MicroCEM analysis enclosure On/Off switch is located inside the door on the bottom right hand corner. Push switch to the “on” position to start system.

The unit will immediately run thru a self diagnostic mode. This may take up to 2 minutes. The user will know the system has passed all diagnostic test and is “ready” upon the green LED (located above on/off switch) flashing. If the green LED does not start to flash verify that proper power is connected to the unit and restart. If AC/Heater fan is running but the green LED still will not flash then call the factory immediately for help.

NOTE: After startup a warm-up time from 20 to 60 minutes (Depending upon ambient temp) is required for accurate measuements.

Analyzer operation can be confirmed by the green LED light flashing. The pocket pc can then be connected for viewing menus. Upon power up, the analyzer will perform a self-test routine. The test will take approximately 6 minutes.

4.2 Analyzer Operation

4.2.1 User Interface

The µCEM User Interface runs on a Pocket-PC with Windows CE operating system. It communicates with the µCEM via serial communication port. All input to the Pocket-PC is done using a pointing device that comes with the Pocket-PC. The Pocket PC can be plugged into two different ports. The first port is located on the front panel below the on/off switch inside the front door. The second port is from the bottom of the uCEM via

J3 connector.

The pocket PC can be found behind the door behind the glass piece. Note that upon shipment the pocket PC may be located in a separate box.

To connect the pocket PC to the: µCEM via the inside connection.

1. Open µCEM door.

2. Plug RS232 plug into adapter located on front panel

3. Plug power supply cable into 5V adapter

4. Turn Pocket PC on

5. In order to assure no other windows are open press the reset button. Reset button is located on the back of the pocket PC.

6. Go to tools menu (Icon in upper left hand corner) and click on µCEMTS.

7. Unit will display data in 3 to 5 seconds. If unit does not show data in 3 to 5 seconds repeat procedure starting with number 5.

To connect the pocket PC to the: µCEM via the outside connection.

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CEM

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STARTUP and OPERATION

1. Plug the external COM cable into J3 circular connector on the bottom of the uCEM.

2. Plug pocket pc RS232 plug into the J1 on the external COM cable.

3. Plug power supply cable into 5V plug on the COM cable.

4. Turn Pocket PC on.

5. In order to assure no other windows are open press the reset button. Reset button is located on the back of the pocket PC.

6. Go to tools menu (Icon in upper left hand corner) and click on µCEMTS.

7. Unit will display data in 3 to 5 seconds. If unit does not show data in 3 to 5 seconds repeat procedure starting with number 5.

Note: The Pocket PC can by used on any MicroCEM TS analysis enclosure regardless of the MicroCEM units IP address.

4.2.2

µ

CEM Main Window

The µCEM Main Window shown in Figure 4-1 provides the status of the three emissions channels. The status includes the current reading (updated approximately every 2 seconds), the last 1-minute average, and the last 15-minute average. The status column

(Sts) indicates the status of the measurement and can be any of the values in the Table

4-1.

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

4-2

Shown in order of precedence.

Maintenance mode status takes highest precedence.

STARTUP and OPERATION

Table 4-1 - Status Values

Status Description

M Indicates that maintenance mode is active.

C

I

Calibration in process

Invalid Reading. Indicates that the reading is invalid due to calibration failure or Low Pressure flow alarm.

P

B

O

Customer Process Off Line (Dry contact by cust)

System is in By-Pass mode (Stream Switch)

µCEM System powered off

Drag the edges of the columns to resize the columns

Use the scrollbar to see the full set of data

Figure 4-1 -

µ

CEM Main Display

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CEM

Continuous Analyzer Transmitter

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STARTUP and OPERATION

4.2.3

µ

CEM Menus

Lower left part of the µCEM screen contains three menus, from which all of the µCEM user-interface functions can be accessed. There are three main menus: File, Tools and

Advanced, presented on Figures 4-2.1, 4-2.2, and 4-2.3.

File Menu

: Provides General access to Connect, Log-in, Log Off features

Tools Menu

: Provides access to basic

µ

CEM Tools, like alarms and stream switching

Advanced Menu

: Provides access to advanced

µ

CEM Features, like Stream Settings and User Administration

Toolbar Buttons

: Shortcuts to Alarms,

µ

CEM Settings,

µ

CEM Admin, Stream Switching

Tools Menu

: Provides access to all functionality

Note:

Exit will only be available when current user has administrative access

Figure 4-2.1 -

µ

CEM File Menu

Toolbar Buttons

: Shortcuts to Alarms,

µ

CEM

Settings,

µ

CEM Admin.,

Data Logs and About

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CEM

Continuous Analyzer Transmitter

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STARTUP and OPERATION

Figure 4-2.2 -

µ

CEM Tools Menu

Figure 4-2.3 -

µ

CEM Advanced Menu

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CEM

Continuous Analyzer Transmitter

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STARTUP and OPERATION

4.2.4

µ

CEM Alarms

The µCEM Alarms dialog shows all the current alarms. A current alarm is one with an

Active status of 1 (active) or an Acknowledged state of 0 (not acknowledged).. To see the historical Alarms for the last 3 months , the web based µCEM interface must be used. If one or more alarms are current, the most recent of them will be displayed on the main display. If more than one alarm is current “(more)” will be displayed after the name of the most recent alarm on the main window to indicate that more than one alarm is active. Horizontal scroll bar is be used to see Date and Time of the Alarms. Alarms can be General and Stream-specific. By selecting the radio buttons on the bottom, user can view different types of alarms.

Drag the edges of the columns to resize the columns

Use the scrollbar to see the full set of data

Alarm Name

O2 Calibration

Failed

CO Calibration

Failed

NOx Calibration

Failed

Figure 4-3. Pocket PC Alarms Screen

Alarms with a critical level will cause the System trouble output to become active when the alarm is active. When all active critical alarms are acknowledged, the System trouble output will become inactive.

Level

Critical

Critical

Critical

Description

O2 Calibration Failed to meet the maximum Drift requirements

CO Calibration Failed to meet the maximum Drift requirements

NOx Calibration Failed to meet the maximum Drift requirements

Type

Stream

Specific

Stream

Specific

Stream

Specific

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STARTUP and OPERATION

O2 High Limit

O2 Low Limit

CO High Limit

CO Low Limit

NOx High Limit

Critical

Critical

Critical

Critical

Critical

O2 Sensor reading is above the minimal acceptable limit

O2 Sensor reading is below the minimal acceptable limit

CO Sensor reading is above the minimal acceptable limit

CO Sensor reading is below the minimal acceptable limit

NOx Sensor reading is above the minimal acceptable limit

Nox Low Limit

24V Over Max

24 Low Min

Critical

Critical

Critical

O2 Emission Limit Warning O2 reading is over the specified

Limit

CO Emission Limit Warning CO reading is over the specified

Limit

NOx Emission Limit Warning NOX reading is over the specified

Limit

Converter Over

Temp

Critical Converter temperature reading exceeds the specified maximum

Converter Low

Temp

Zone Over Temp

Critical

Critical

Converter temperature reading is below the specified minimum

Zone temperature reading exceeds the specified maximum

Zone Low Temp Critical

NOx Sensor reading is below the minimal acceptable limit

24V diagnostic input exceeds the specified maximum

24V diagnostic input is below the specified minimum

PDT Over Temp

PDT Low Temp

PMT Over Temp

PMT Low Temp

Low Pressure

Critical

Critical

Critical

Critical

Critical

Warmup Time Limit Critical

Zone temperature reading is below the specified minimum

Peltier Cooler (PDT) temperature reading exceeds the specified maximum

Peltier Cooler (PDT) temperature reading is below the specified minimum

PDD Chamber temperature reading exceeds the specified maximum

PDD Chamber temperature reading is below the specified minimum

Low Sample Flow Pressure is detected (Below 2.5psi)

System Warm-up process exceeded the specified time limit

Table 4-2 – Alarm Summary

General

General

General

Stream

Specific

General

Stream

Specific

Stream

Specific

Stream

Specific

Stream

Specific

Stream

Specific

Stream

Specific

General

General

Stream

Specific

Stream

Specific

Stream

Specific

General

General

General

General

General

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CEM

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STARTUP and OPERATION

4.2.5

µ

CEM Login

The login dialog appears (Figure 4-4) when first requesting the µCEM Settings or µCEM

Admin. If a valid user name and password are entered, the user logging in will have permission to use the µCEM Settings and/or the µCEM Administration (Refer to the User

Settings page of the µCEM Settings dialog). After logging in the first time, it is not required again until the user logs out, or is logged out automatically because of a period of inactivity (Refer to the Auto Logout page of the µCEM Administration dialog).

Figure 4-4 -

µ

CEM Login

On-screen keyboard is available at any time by clicking on the keyboard button.

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CEM

Continuous Analyzer Transmitter

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STARTUP and OPERATION

4.2.6

µ

CEM Login-Current User Indication

When a user is logged in, the µCEM main display will indicate the user name of the logged in user as shown in Figure 4-5.

Figure 4-5 - Current User Indication

Current user and

Log off button.

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µ

CEM

Continuous Analyzer Transmitter

4-9

STARTUP and OPERATION

4.2.7 Stream Switching Control

Typically a dual stream system is in Automatic Stream Switching mode. That means that it runs the timing schedule specified in User Settings Configuration file. If Automatic switching is not desirable, the user may turn it off using Tools-> Stop Auto Switching menu. In this case the system will remain on the current stream indefinitely. When

Automatic switching is needed again, user may turn it back on with Tools->Start Auto

Switching menu.

The same task can be accomplished remotely, by clicking Stop Auto Switching button on the µCEM Real-Time Web page.

Note, that this option is sustained even if the system is rebooted.

The operator may also force a switch between the streams at any time whether the system is in Auto-Switching mode or not. Tools menu has an option “Switch to

StreamName”, where StreamName is a user-specified name of the stream.

The same task can be accomplished remotely by clicking Switch to “StreamName” button on the µCEM Real-Time Web page.

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µ

CEM

Continuous Analyzer Transmitter

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STARTUP and OPERATION

4.3

µ

CEM Settings

The µCEM Settings dialog is only available to users with µCEM Settings permission. If a user is not currently logged in, the login dialog will be displayed. If the current user doesn’t have µCEM Settings permission, µCEM will not allow Settings screen to appear.

When the µCEM Settings are invoked from the Advanced menu or the µCEM Settings button, the µCEM Settings tabbed dialog is displayed. The Range page (tab) is displayed initially.

4.3.1

µ

CEM Settings-Range

The Range Settings page is used to specify the range for the analog outputs.

Setting

Range 2 to a value of 0 (zero) enables single range functionality and disables the dual range function.

For Dual Range applications do not set range 2 equal too or higher than Range 1 or the system will not calibrate properly. Note that Range 1 can be changed by the user but must be changed in the webrowser tools. See the Webrowser user settings section.

The dual range setting will enable the analyzer software and diagnostics to perform two separate performance curves for each range thus enhancing the measuring capabilities of the analyzer. A dual range setting is desired for applications burning dual fuels or that may display high dynamic reading between the low and high of the day. The analog outputs will also support the dual range mode. When the emission is below the Range 2 value, the analog output will switch to Range 2 mode and the Range 2 value becomes the full-scale value of the analog output. The range indication digital output will change to the Range 2 state. When the emission is above the Range 2 value, the output switches to Range 1 mode and the Range 1 value becomes the full-scale value of the output. The range indication digital output will change to the Range 1 state.

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CEM

Continuous Analyzer Transmitter

4-11

STARTUP and OPERATION

Figure 4.6 - Range Settings

The Tabs allow selection of the

µ

CEM

Settings pages.

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CEM

Continuous Analyzer Transmitter

4-12

STARTUP and OPERATION

4.3.2

µ

CEM Settings-Auto Calibration

The Auto-Calibration settings are set on the Auto-Calibration page of the µCEM settings.

If auto calibration is turned to the on position, then the user can select time and/or frequency of the auto calibration in the Auto Calibration Frequency tab (4.3.3).

Note: Both manual and auto calibration need to be perform with the MicroCEM enclosure door in the closed position. If the door is opened then critical detector temperatures will vary which will cause a drift in the calibration. If the door is kept open long enough for temps to be constant at their setpoints then an open door calibration is acceptable. See section 4.7 “temp diagnostics”- for details on temperature setpoints.

Figure 4.7 - Auto Calibration Settings

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CEM

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STARTUP and OPERATION

4.3.3

µ

CEM Settings - Auto Calibration Time and Frequency

The Auto-Calibration Time and Frequency tab allows specifying time and frequency of the auto-calibration. Time field requires military time format. The times are displayed in

Military time type.

Figure 4.8 - Auto Calibration Time and Frequency

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CEM

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STARTUP and OPERATION

4.3.4

µ

CEM Settings-Limits

The emission limits alarms can be set on the Limits page of the µCEM Settings. When a measured emission exceeds its limit, the emission will have a limit-exceeded status.

This is indicated on the main display and on the Data-Logs display. It is also indicated in the limit exceeded digital output.

Figure 4.11 - Limit Settings

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CEM

Continuous Analyzer Transmitter

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STARTUP and OPERATION

4.3.5

µ

CEM Settings-Calibration Gas

The Calibration Gas values and Gas Bottle allocation may be set on the Calibration Gas page of the µCEM Settings. This should be set whenever a Calibration Gas container is replaced or upon Startup of the system.

Calibration Gas Values

:

R1Mid: This is typically used for CGA audits and not for daily calibrations. The specific calibration gas mid value (typically between 40% to 60% of range) is set in this space.

The MicroCEM will perform mid calibration on Range 1 on this gas but will not perform any corrections. This box should typically be left blank. It is mostly used as a check.

R1Span: The specific calibration gas span value (typically between 80% to 100% of range) is set in this space for Range 1. A Nox range of 0-100ppm would typically use a gas bottle with 90ppm NOx balance N2.

R2Mid: This is typically used for CGA audits and not for daily calibrations. The specific calibration gas mid value (typically between 40% to 60% of range) is set in this space.

The MicroCEM will perform a mid calibration on Range 2 on this gas but will not perform any corrections. This box should typically be left blank. It is mostly used as a check.

R2Span: The space is allocated for dual range applications. If the MicroCEM range setting is set for single range then the user will not be able to input any value into this space. The specific calibration gas span value (typically between 80% to 100% of range) is set in this space. A Nox range of 0-10ppm would typically use a gas bottle with

9ppm NOx balance N2.

Note that zero values do not have to be input into this page. For all zero calibrations the user must assure that the calibration gas used does not have any levels of the measurement gas in the cylinder. For example upon the analyzer zeroing O2, the bottle used must have 0% O2 in the Bottle. Zeroing the O2 is typically performed by using the

NOx or CO Span gases.

Gas Bottle Allocation:

Gas 1, Gas 2 and Gas 3 are labels for the respective location of where the calibration gas cylinders are physically located on the external fittings.

Off: Designates that no operation will be performed.

Zero: The MicroCEM will perform a zero calibration.

R1Span: MicroCEM will perform a Span calibration for Range 1.

R2Span: MicroCEM will perform a Span calibration for Range 2. Note that if a second range is NOT chosen in the range settings menu then user will not be able to input any value into this space. Range 2 should always be a lower value than range 1 if used.

R1Mid: MicroCEM will perform a Mid Calibration for Range 1.

R2Mid: MicroCEM will perform a Mid Calibration for Range 2. Note that if a second range is NOT chosen in the range settings menu then user will not be able to input any value into this space.

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CEM

Continuous Analyzer Transmitter

4-16

STARTUP and OPERATION

Figure 4.12 - Calibration Gas Settings

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CEM

Continuous Analyzer Transmitter

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STARTUP and OPERATION

4.3.6

µ

CEM Settings-Maintenance Mode

Maintenance mode may be selected for any of the emission types on the Maintenance

Mode page of the µCEM Settings.

Choosing maintenance mode will invoke an “M” flag” onto the data. Customer can perform routine maintenance while in this setting

This mode is typically used when preventive maintenance is being performed. The M flag signifies to the EPA that the values reported are not valid therefore should not be applied to emissions reporting.

Upon completion of Maintenance the user must go back into this screen to turn the

Maintenance off. If not, the MicroCEM will continue to show the M flag in the data.

Figure 4.13 - Maintenance Mode Settings

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CEM

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STARTUP and OPERATION

4.3.7

µ

CEM -Manual Calibration

A dry-run Calibration may be initiated from the Manual Calibration page of the µCEM

Settings by pressing the Manual Calibrate All icon. A full zero and span calibration will be run by the MicroCEM but the end result corrections of the calibration will not be applied to the O2/Nox/CO measurement values. If desired a partial calibration may be invoked for one or more of the emission types. While the manual calibration is in process, a calibration progress dialog will be displayed as shown in Figure 4.24. When the manual calibration is completed, the results are displayed in the Manual Calibration

Results dialog as shown in Figure 4.10. If the Local Calibration checkbox is checked, the Local Calibration valve will be used during the calibration rather than the probe

Calibration valve.

Note that “Start Auto Cal now” will invoke a calibration and will apply new correction factor to all measurement when done.

Figure 4.9 - Manual Calibration Menu

Rosemount Analytical

µ

CEM

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4-19

STARTUP and OPERATION

4.3.8 Auto Calibration

The Auto Calibration dialog is displayed whenever calibration is in process. It displays the current emission values and the status of the calibration. The calibration may be canceled before it completes by pressing the Cancel button.

Note: The title of this dialog will read either “Auto Calibration” or

“Manual Calibration” to indicate how the calibration process was initiated.

Figure 4.22 - Auto Calibration Status Screen

Figure 4.10 - Manual Calibration Results

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

Use the scrollbar to see the full set of results

4-1

STARTUP and OPERATION

4.4

µ

CEM Administration

The µCEM Administration dialog is only available to users with µCEM Administration permission. If a user is not currently logged in, the login dialog will be displayed. If the current user doesn’t have µCEM Administration permission, a message will be displayed which reads “Permission denied”. When the µCEM Administration is invoked from the

Tools menu or the µCEM Administration button, the µCEM Administration tabbed dialog is displayed. The User Settings page (tab) is displayed initially.

4.4.1

µ

CEM Administration-User Settings

The user settings page of the µCEM Administration dialog allows users to be added, deleted or modified. Each user has a name, password, and permission settings. The permission settings include Settings permission that allows access to the µCEM Settings dialog, and Administrative permission that allows access to the µCEM Administration dialog. The Settings permission also allows a user to access the µCEM remotely using the web-based interface.

Figure 4.14 - User Settings

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CEM

Continuous Analyzer Transmitter

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STARTUP and OPERATION

4.4.2

µ

CEM Administration-Auto Logoff

The number of minutes of inactivity after which a user is automatically logged off is set on the Auto Logoff page of the µCEM Administration.

Figure 4.15 - Auto Logoff

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CEM

Continuous Analyzer Transmitter

4-3

STARTUP and OPERATION

4.5

µ

CEM Factory and User Settings

A µCEM Factory and User Settings files are available for use by µCEM technicians to set parameters in the µCEM or a qualified customer technician.

µCEM Settings are separated into two files: Factory Settings and User Settings. Factory

Settings should be modified by a Rosemount technician only. Note: Some parameters in this file, if set incorrectly, may cause permanent damage to hardware.

User Settings can be modified by a qualified customer technician. User settings are accessible through the User Settings Web screen. See section 4.7 for details on access. Settings files are formatted as a standard Windows INI files. File is organized in sections (in square brackets). Configuration Parameters are presented in “Name =

Value” format. Comments start with semicolon. User Settings files has three sections

[General], [Stream 1] and [Stream 2].

The list of some settings is shown in Table 4.3 & Table 4.4.

Consult a Rosemount factory person for details.

Rosemount Analytical

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CEM

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STARTUP and OPERATION

Table 4.3 - [General] section

Calibration Setting

Stream1Time

Stream2Time

TransitionTime

Stream1Name

Stream2Name

CalibrationCurrentLoopOutputs

ByPassCurrentLoopOutputs

AutoCalForcesSwitch

DigitalOutputsLogic

Description

Stream 1 processing time in minutes when auto switching

Stream 2 processing time in minutes when auto switching

Time to keep the B flag after the switch have occurred, in seconds

Stream 1 Name to be shown on Pocket PC and Web pages

Stream 2 Name to be shown on Pocket PC and Web pages

Defines the behavior of Current Loops during Calibrations

1 - Hold the Last Good Value,

2 - Use the User-Specified Value

3 - Follow the Gases as is set to 2

Defines the behavior of Current Loops during By-Pass

1 - Hold the Last Good Value

2 - Use the User-Specified Value set to 2

Defines what to do, when the scheduled Auto-Calibration time comes, but the system happens to process another stream

1 - force a switch to the stream and run the Calibration

2 - wait until the stream is switching occures by itself and run the Calibration

Defines how to control Digital Outputs

1- O2 Limit, CO Limit, NOX Limit Logic

2- Valid, In Calibration, In Maintenance

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STARTUP and OPERATION

Table 4.4 - [Stream X] section

Stream Setting Description

DiluentCorrectionPercent Diluent Correction Percent used in calculations for the Stream

O2R1Range

COR1Range

NOXR1Range

PostCalibrationDelay

Range 1 Setting for O2 (Range 2 can be changed from the Pocket PC)

Range 1 Setting for CO (Range 2 can be changed from the Pocket PC)

Range 1 Setting for NOx (Range 2 can be changed from the Pocket

PC)

Number of seconds to keep the C(Calibration) flag after the Auto

Calibration process is over

R1O2ZeroDriftLimit

R1COZeroDriftLimit

R1NOXZeroDriftLimit

R1OSMidDriftLimit

R1COMidDriftLimit

R1NOXMidDriftLimit

R1O2SpanDriftLimit

O2 Allowed Zero Drift

Limit for Range 1.

CO Allowed Zero Drift

Limit for Range 1.

NOx Allowed Zero Drift

Limit for Range 1.

O2 Allowed Mid Drift Limit for Range 1.

CO Allowed Mid Drift

Limit for Range 1.

NOx Allowed Mid Drift

Limit for Range 1.

O2 Allowed Span Drift

Limit for Range 1.

If the drift exceeds the allowed amount a drift alarm will occur, and the readings on the channel will no longer be valid until a successful calibration is completed.

R1COSpanDriftLimit

R1NOXSpanDriftLimit

R2O2ZeroDriftLimit

R2COZeroDriftLimit

R2NOXZeroDriftLimit

R2OSMidDriftLimit

R2COMidDriftLimit

R2NOXMidDriftLimit

CO Allowed Span Drift

Limit for Range 1.

NOx Allowed Span Drift

Limit for Range 1.

O2 Allowed Zero Drift

Limit for Range 2.

CO Allowed Zero Drift

Limit for Range 2.

NOx Allowed Zero Drift

Limit for Range 2.

O2 Allowed Mid Drift Limit for Range 2.

CO Allowed Mid Drift

Limit for Range 2.

NOx Allowed Mid Drift

Limit for Range 2.

If the drift exceeds the allowed amount a drift alarm will occur, and the readings on the channel will no longer be valid until a successful calibration is completed.

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R12O2SpanDriftLimit

R2COSpanDriftLimit

R2NOXSpanDriftLimit

O2 Allowed Span Drift

Limit for Range 2.

CO Allowed Span Drift

Limit for Range 2.

NOx Allowed Span Drift

Limit for Range 2.

4.6 uCEM Data Logs

The µCEM maintains a minimum of 3 months of history in three types of data log files.

The first type of log file is the measurement log, which contains emission measurements

(at 1 minute intervals), alarm indications and maintenance mode indications. The second type of log file is the calibration log file, which contains information on each auto calibration done. The third is the alarm log file, which records any improperly functioning hardware. The data will be stored in flat, ASCII, CSV (comma-delineated) files. This file format can be read directly by MS Excel and imported into many types of software applications. The following parameters are factory set for each of the log file types.

4.6.1 Maximum Log File Size

This is how large a log file can get (in bytes) before it is closed and a new log file is opened.

Emissions Log:

Calib Log:

Alarm Log:

1 MB

4000 bytes

4000 bytes

4.6.2 Maximum Number of Log Files

This is how many log files can be created. When the maximum number of log files is reached, the oldest file is overwritten when new ones are created.

Emissions Log:

Calib Log:

Alarm Log:

6

6

6

4.6.3 Log File Name Format

The log file name uses the date that the file was created. It is of the format

TYYYYMMDD

.CSV where

T

is the log file type (E=Emissions, C=Calibration and

A=Alarm),

YYYY

is the Year,

MM

is the month, and DD is the day of the month. For example, the file name

E20010329.csv

contains emissions data and was created on

March 29, 2001.

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4.6.4 Measurement Log File Format

The log file contains data in a flat, ASCII, CSV file. The following are the fields of the file, in order of occurrence. The log file size will be about 42 bytes per entry. 3 months of data logs will require about 5,443,200 bytes

Name Description Example

O2

O2 Limit

O2 Status

Percent O2 (percent)

O2 Limit exceeded alarm, 0=inactive,

1=active

V=Valid, M=Maintenance Mode,

C=Calibration in process, I=Invalid

(calibration failed or sensor in failed state)

CO parts per million CO

CO Limit

CO Status

CO Limit exceeded alarm, 0=inactive,

1=active

V=Valid, M=Maintenance Mode,

C=Calibration in process, I=Invalid

(calibration failed or sensor in failed state)

NOx parts per million Nox

NOx Limit NOx Limit exceeded alarm, 0=inactive,

1=active

NOx Status V=Valid, M=Maintenance Mode,

C=Calibration in process, I=Invalid

(calibration failed or sensor in failed state)

Table 4.7 –Measurement Log File Format

10:24:00

10.5

0

V

12

0

V

15

0

V

4.6.5 Calibration Log File Format

The log file contains data in a flat, ASCII, CSV file. The following are the fields of the file, in order of occurrence. The log file size will be about 350 bytes per entry. 3 months of data logs will require about 32000 bytes (based on Calibration performed every 24 hours).

Name Description

Date/Time Calibration start

Month-day-year Hours:Minutes:Seconds

Example

3-7-2001

10:24:57

Gas 1 Time

Gas 2 Time

Gas 3 Time

Purge Time

Time that Gas 1 started, Hours:Minutes:Seconds 10:25:30

Time That Gas 2 started, Hours:Minutes:Seconds 10:27:30

Time that Gas 3 started, Hours:Minutes:Seconds 10:28:30

Time that the final purge started, Hours:Minutes:Seconds 10:30:30

Finish Time

O2 Expected Zero

O2 Measured Zero

O2 Zero Drift

O2 R1 Expected Mid

Span

O2 R1 Measured Mid

Time that the final purge finishes

Expected percent O2 for Zero phase of calibration

Measured percent O2 for Zero phase of calibration

Percent drift of O2 zero calibration

Expected percent O2 for Range 1 Mid span phase of calibration

Measured percent O2 for Range 1 Mid span phase of

10:31:00

0.0

0.0

0.0

10.0

10.1

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Span calibration

O2 R1 Mid Drift Percent drift of O2 Range 1 mid calibration.

O2 R1 Expected Span Expected percent O2 for Range 1 Span phase of calibration

O2 R1 Measured Span Measured percent O2 for Range 1 Span phase of calibration

O2 R1 Span Drift Percent drift of O2 Range 1 span calibration

O2 R2 Expected Mid

Span

Expected percent O2 for Range 2 Mid span phase of calibration

O2 R2 Measured Mid

Span

O2 R2 Mid Drift

Measured percent O2 for Range 2 Mid span phase of calibration

Percent drift of O2 Range 2 mid calibration.

O2 R2 Expected Span Expected percent O2 for Range 2 Span phase of calibration

O2 R2 Measured Span Measured percent O2 for Range 2 Span phase of calibration

0.4

20.2

20.3

0.4

10.0

10.1

0.4

20.2

20.3

O2 R2 Span Drift

CO Expected Zero

CO Measured Zero

CO Zero Drift

CO Expected R1 Mid

Span

CO Measured R1 Mid

Span

Percent drift of O2 Range 2 Span calibration

Expected ppm CO for zero phase of calibration

Measured ppm CO for zero phase of calibration

Percent drift of CO zero calibration

Expected ppm CO for Range 1 mid span phase of calibration

Measured ppm CO for Range 1 mid span phase of calibration

24

CO R1 Mid Span Drift Percent drift of CO Range 1 mid span calibration 0.3

CO R1 Expected Span Expected ppm CO for Range 1 span phase of calibration 45

CO R1 Measured Span Measured ppm CO for Range 1 span phase of calibration 45

CO R1 Span Drift Percent drift of CO Range 1 span calibration 0

23 CO Expected R2 Mid

Span

CO Measured R2 Mid

Span

Expected ppm CO for Range 2 mid span phase of calibration

Measured ppm CO for Range 2 mid span phase of calibration

24

CO R2 Mid Span Drift Percent drift of CO Range 2 mid span calibration 0.3

CO R2 Expected Span Expected ppm CO for Range 2 span phase of calibration 45

CO R2 Measured Span Measured ppm CO for Range 2 span phase of calibration 45

CO R2 Span Drift Percent drift of CO Range 2 span calibration 0

NOx Expected Zero

NOx Measured Zero

NOx Zero Drift

NOx Expected R1 Mid

Span

Measured ppm NOx for zero phase of calibration

Expected ppm NOx for zero phase of calibration

Percent drift of NOx zero calibration

Measured ppm NOx for Range 1 mid span phase of calibration

15

15

0

30

0.4

1

0

-0.3

23

30

NOx Measured R1 Mid

Span

Measured ppm NOx for Range 1 mid span phase of calibration

NOx R1 Mid Span Drift Percent drift of NOx Range 1 mid span calibration

NOx Expected R1 span Measured ppm NOx for Range 1 span phase of calibration

NOx Measured R1 span Measured ppm NOx for Range 1 span phase of calibration

0

59

59

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STARTUP and OPERATION

NOx R2 Span Drift

NOx Expected R2 Mid

Span

Percent drift of NOx Range 1 span calibration

Measured ppm NOx for Range 2 mid span phase of calibration

NOx Measured R2 Mid

Span

Measured ppm NOx for Range 2 mid span phase of calibration

NOx R2 Mid Span Drift Percent drift of NOx Range 2 mid span calibration

NOx Expected R2 span Measured ppm NOx for Range 2 span phase of calibration

NOx Measured R2 span Measured ppm NOx for Range 2 span phase of calibration

NOx R2 Span Drift Percent drift of NOx Range 2 span calibration

Table 4.8 – Calibration Log File Format

0

30

30

0

59

59

0

4.6.6 Alarm Log File Format

The log file contains data in a flat, ASCII, CSV file. The following are the fields of the file, in order of occurrence. The days or months maintained in the Alarm Log depends on how often trouble conditions are recorded. If alarms rarely occur, there is enough space for many years of alarm logs to be recorded.

Name Description Example

Date/Time Month-day-year Hours:Minutes:Seconds 3-7-2001 10:24:57

Fault Level 1=informational, 2=warning, 3=critical 3

Fault Type 0 = O2 Calibration Failed

1 = CO Calibration Failed **

2 = NOx Calibration Failed

3 = O2 High Limit

4 = O2 Low Limit

5 = CO High Limit **

6 = CO Low Limit **

7 = NOx High Limit

8 = NOx Low Limit

9 = O2 Emission Limit

10 = CO Emission Limit **

11 = NOx Emission Limit

12 = 5 Volt Fault **

13 = 6 Volt Fault **

14 = 24V Over Max

15 = 24 Low Min

16 = Converter Over Temp

17 = Converter Low Temp

18 = Converter On Failed **

19 = Converter Off Failed **

20 = Zone Over Temp

21 = Zone Low Temp

22 = Zone Heater On Failed **

23 = Zone Heater Off Failed **

2

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Fault

Description

24 = Zone Cooler On Failed **

25 = Zone Cooler Off Failed **

26 = Heater Fan On Failed **

27 = Heater Fan Off Failed **

28 = Cooler Fan On Failed **

29 = Cooler Fan Off Failed **

30 = PDT Over Temp

31 = PDT Low Temp

32 = PDT On Failed **

33 = PDT Off Failed **

34 = PMT Over Temp

35 = PMT Low Temp

36 = PMT On Failed **

37 = PMT Off Failed **

38 = O2 Over Temp **

39 = O2 Low Temp **

40 = O2 On Failed **

41 = O2 Off Failed **

42 = Warmup Time Limit

55 = Low Pressure

70 = IO Board Failed

71 = Disk Failure

72 = Network Failure

ASCII string describing fault. Up to 200 characters.

CO Calibration Failed

Table 4.9 – Alarm Log File Format

** - Alarm is not implemented in this version of software or reserved for the future use

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4.6.7 Accessing the Real-Time ACSII Data String via Ethernet TCP/IP

(DAS)

Remote Real-time data acquisition from the uCEM is done through the TCP/IP enabled network via the HTTP (Web transport) protocol.

Acquisition software has to request the page form the Web Server running on the uCEM unit with the desired frequency (real update time is 1 sec).

URL for the real time data is defined as such: http://[uCEM IP]/fetchData.asp

For example: http://127.0.0.1/ fetchData.asp

In response Web Server will return the comma-delimited string that contains current analyzer data. Note: the response is a plain text not the HTML document.

If the actual analyzer software is running, the response data will be formatted as such:

DateTime,O2CurrentValue,O2CurAlarms,O2Status,O21MinAverage,O21MinStatu s,O215MinAverage,O215MinStatus,COCurValue,COCurAlarms,COCurStatus,CO

1MinAverage,CO1MinStatus,CO15MinAverage,CO15MinStatus,NOxCurValue,N

OxCurAlarms,NoxCurStatus,NOx1MinAverage,NOx1MinStatus,NOx15MinAverag e,NOx15MinStatus,ExtProcess1,ExtProcess2,DigInput1,DigInput2,DigInput3;

AlarmsString

The result is a single string of data.

DateTime

is formatted as such: Month-Day-Year4Digits HoursMilitary:Minutes:Seconds

Example: 02-05-2002 14:58:53

All the current and average gas values are the floating-point numbers and may contain a sign. Certain rules are defined for the current and average gas values:

If there is a “#” sign in this field – data for this field are not valid. That usually means there is no data available or the data cannot be converted to the string representation (due for example to faulty Calibration).

If the value field shows –

-555.00” (negative 555.00). That is a “magic number” that denotes that the system haven’t yet initialized the data. That usually happens when uCEM starts up and 1 minute or 15-minute averages are not yet available (calculated). Note that regardless of the status, values show the current measured data from the analyzer. “Magic number” means that the data (usually 15 minute averages) have not been yet calculated.

ExtProcess1

and

ExtProcess2

are the values of the Analog Inputs (Mega Watts and Fuel

Flow usually).

DigInput1

,

DigInput2

,

DigInput3

- show the state of the digital inputs and can take a value of either 1(On) or 0(Off). DigInput1 is usually interpreted as ProcessOn. DigInput2

– as FlameOn. DigInput3 – as Shutdown.

CurAlarms

values show the current state of the emissions limit alarm associated with the gas. It’s an integer number that equals to 1 when emission limit for the gas is exceeded and stays 0 if the gas doesn’t gave associated alarm active.

All the

Status

values are single-character values. Status is defined as such:

V – Valid

I – Invalid

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M – Maintenance

C – Calibration

P – Process Off

O – uCEM Off

AlarmsString

– is a string data that describes the current Alarms situation with the uCEM module. It is separated from the rest of the data by a semi-colon. AlarmsString usually is not parsed and used for the presentation purposes only. Example: “1,NOx

Emission Failed. 13 More ...”

Example:

02-05-2002 14:58:53,21.44,1,V,20.09,V,-555.00,V,##.##,0,P,##.##,P,##.##,P,10.37,1,I,

12.45,I,-555.00,I,5.0,3.76,0,1,0;1,NOx Emission Failed. 13 More ...

This string means that the sample was taken February 5 2002 at 2:58PM, O2 values were all Valid except the 15 Minutes average was not yet calculated, CO process was Off - the data were not available. NOX data were Invalid and the 15 Minutes average was not yet calculated. Mega Watts value read from the input was 5.0, Fuel Flow – 3.76

DigInput1(ProcessOn) is set to 0(Off), DigInput2(FlameOn) is set to 1 (On),

DigInput3(Shutdown) is set to 0 (Off)

There were also 13 alarms active, NOx Emission Failed being the most recent one.

If the uCEM analyzer is not currently running the return string will be:

“uCEM is not running. No data Available.”

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4.7 Viewing Data via the Pocket PC Web Browser

The Pocket PC Web Browser menu can be accessed via the pocket pc main menu. In the top upper left hand corner of the menu the name of the unit will be displayed (ucem

XXXX). Point on this name. A drop down menu will appear. Point on Internet Explorer.

A sign on page will then be displayed. User name and password will be the identical as the normal names used on the administration settings. Very importantly the Web

Browser function allows the user to access all data (calibrations, alarms, emission data logs, diagnostics) internally stored in the MicroCEM.

The Web Browser will show the following screens/options for the user. Note that these screens are updated once every 10 seconds unless the refresh bottom is pressed:

Real Time:

This screen is identical to the main menu screen normally shown on the pocket pc.

Emissions

: This screen will enable the user to view all internal emission data logs stored in the MicroCEM. User can choose between 1, 15, 1hr or 24 hour periods. A designated time frame or most recent data can be choses. The report generator will display data in a chart type format showing each gas value and associated time along with data flags. The function is very helpful in very historical data or performing trouble shooting.

Alarms:

This screen will allow the user to display all alarms and time frames. User may choose time frames or most recent alarms.

Cal:

Display of all calibrations with results can be viewed from this page.

User Config:

This file contains user selectable files that are typically input at startup and never changed. See section 4.4 for details on descriptions. Note that reboot of the

MicroCEM may be necessary for system to accept changed for several items in this file.

Factory Config: Do not access this file unless a certified Rosemount technician is present. Changes to this file may adversely affect or destroy the unit.

Changes made to this file without the written consent of the MicroCEM Product Manager will void the warranty.

Download:

User can easily download all data log files (Emissions, Alarms, Calibrations) stored in the MicroCEM. This is typically used when user is accessing the MicroCEM via a separate laptop or tabletop computer. See next section.

Temp Diag:

Temperature diagnostics is a very important tool for diagnosing existing problems or potential issues/problems with the MicroCEM.

The following parameters will be shown: Temperature Parameter, Temp Setting, Actual

Temp and Integral %.

*Zone Temperature: Zone temperature is typically set to 47 degrees C. This is the temperature of the MicroCEM taken from the detector section thermocouple that is located behind the pressure gauge. This thermocouple is always used for systems with no CO. For systems with CO a thermocouple is located on the CO assy detector. The

MicroCEM will typically control temperature to within +/- 1 degree C. Depending upon the outside ambient temperature the % on time can be from 0 to 100% on. If a negative value is shown in the integral then cooling is in process. Variations greater than 1 degree C will lead to gas measurement drifting.

*PMD Temp: This is the Temperature of the chassis of the MicroCEM. Thermocouple is located in the PMD detector. Temperature is typically within 2 degrees C. of the zone. If the temperature drifts greater than this. Upon first turn on of the MicroCEM this temp can be monitored. Once this temp is within 2 degrees C of the Zone then the unit is ready for accurate measurements. Temperature above the 2 degree variance of the

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STARTUP and OPERATION zone may show than the AC/Heater unit fan may have failed or a possible defective thermocouple.

*PDD Temp: For systems with NOx a cylindrical NOx detector assy is located in the detector section. Internal to the detector assy a small peltier device is operating and must operate at 0 degrees C. The temperature should never deviate +/- .05 degrees C from the setpoint of zero or the NOx readings may drift. Integral will typically run between 40 to 70%.

*PMT Temp: This temperature is for the detector assy heater core. Setting is set to 52 degrees C. Temperature should not drift more than 0.2 degrees C or NOx drift may occur. Excessive temperature variation may be caused by either poor zone temperature control or a faulty heater.

*Conv Temp: This temperature is for the NOx converter assembly. Temperature setting is 330 degrees C. Temp should not vary more than 1 degrees C. or NOx measurements will drift. A faulty heater will cause temp variations.

Note that when the enclosure door is opened that all of the above temperature setting may be affected and will take a short about of time to react and control to the desired temperatures.

Note

: The page header was scrolled out of view to show all the selection options, but it can be seen in Figure 4.17

If Most Recent is selected, the month day and hour do not need to be selected.

Select 1 min., 15 min.,

1 hour or 24 hour averages.

Select the ending hour to view (applicable only to 1 minute averages)

Figure 4.16 - View Data Logs

Table 4.10 - Average Period Selection

Average Period

1 Minute

15 Minutes

1 Hour

24 Hours

Time Range

Displayed

1 Hour

1 Day

3 Days

3 Months

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STARTUP and OPERATION

Note:

The Real-time, Config and Download are included in the navigation menu but these pages are intended for remote desktop use. As an enhancement these items could be hidden if the pages are browsed from a Windows CE version of Internet Explorer.

Alarms and

Calibration data may also be viewed.

A Date is shown for

1 min or 15 minute averages. A date range is shown for 1 hour or greater averages.

The Emission Data-

Logs data is shown here.

7Figure 4.17 - View Data Logs Table

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4.8 Viewing

µ

CEM Data with an external PC Web Browser

The MicroCEM internal log files may be accessed using a user PC or laptop with a web browser that has access to the µCEM over a LAN, serial port connection (PPP) or

Dialup Connection (RAS). The µCEM has Window CE Web Server installed and provides a Web-based interface to select and download the Data-Log files. The downloaded Data-Log files will be in a CSV (comma delineated ASCII) format. The log files may also be viewed as a web page in a tabular format.

1. Connect user PC or laptop to the MicroCEM via Ethernet LAN circular connector located on J4 connector. The Ethernet cable can then be routed to the users

Ethernet hub where as many PC’s as desired can access the MicroCEM Web

Browser. Customer may also choose to connect the cable directly to the

Ethernet port located on the MicroCEMs PC104 PCB which is internal to the

MicroCEM. Note that a crossover type Ethernet cable must be used if a hub is not utilized.

2. The user PC or laptop must have the same IP address as the MicroCEM or the

MicroCEM IP address can be changed to the users desired IP address.

Standard IP address of the MicroCEM is:

192.168.1.92

3. Once the IP addresses are matched the user can simply open internet explorer on their computer and type is the MicroCEMs IP address.

4. Once entered a user ID and password must be entered. These are the identical user ID and password as input into the administration menus.

5. Once entered the user can then access all pages as specified in section 4.7.

4.8.1 Real-Time Page

The Real-Time page provides a real-time display of the emission values and emission statuses. The display is refreshed every 10 seconds.

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STARTUP and OPERATION

Figure 4.18 - Real-Time Web Page

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STARTUP and OPERATION

4.8.2 Emissions Page

The Emissions Page can be used to view emission history in a tabular web-page format.

This page is used as part of the µCEM User interface as well as by a remote user

(probably from a desktop computer).

If Most Recent is selected, the month day and hour do not need to be selected.

Select the ending hour to view (applicable only to 1 minute averages)

Select 1 min., 15 min.,

1 hour or 24 hour averages.

Figure 4.19 – Emissions Selection

The Emission Data-Logs table is displayed (as shown in figure 4.19) after selecting the

Date and Average Period and pressing the Display button. If desired a bookmark or shortcut may be made to the page displaying the table. In the future, the same table can be displayed by selecting this bookmark. If Most Recent Data was selected, the bookmarked page will always display Most Recent Data. If a specific date was specified, the book-marked page will always display the same date.

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Figure 4.20 - Emissions Table

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Figure 4.21 - Calibration Table

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4.8.3 Download Page

The download page of the µCEM allows the selection and download of the three types of

Data-Logs. To quickly download recent data, a “Download Most Recent Emissions

Data” selection is provided. For more control over the date range, a “Download

Emissions by Date Range” selection is available. Once the selection is made, press the

Download button to start the HTTP download. The µCEM will create a temporary file that contains the selected data. Due to memory limitations there is a limit to the number of files that can be downloaded simultaneously. If this limit is exceeded, a message will be displayed that reads “The simultaneous download limit has been reached, please try again later”.

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STARTUP and OPERATION

Download Emissions

Log, Calibration Log or Alarm Log

Choose from:

1 Minute / 8 Hours

1 Minute / 1 Day

1 Minute / 1 Week

15 Minutes / 1 Day

15 Minutes / 1 Week

15 Minutes / 1 Month

15 Minutes / 3 Months

1 Hour / 1 Week

1 Hour / 1 Month

1 Hour / 3 Months

Figure 4.22 - Download Web Page

4.9 Viewing

µ

CEM Data with MS Excel

The µCEM Data may be viewed with MS Excel. CSV comma delineated files can be opened either from the Web browser Session or after the file(s) are saved onto a workstation. The files may then be opened directly with Excel. These files later can be converted and saved in MS Excel native format to enable charting and other secondary analysis functions.

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MAINTENANCE and SERVICE

5. Maintenance and Service

CAUTION: QUALIFIED PERSONNEL

This equipment should not be adjusted or repaired by anyone except properly qualified service personnel.

WARNING: PARTS INTEGRITY

Tampering with or unauthorized substitution of components may adversely affect safety of this product. Use only factory-approved components for repair.

WARNING: ELECTRICAL SHOCK HAZARD

components.

Disconnect power to the module(s) prior to replacing

The uCEM Analyzer Module requires very little maintenance during normal operation.

5.1 Overview

The uCEM Analyzer Module requires very little maintenance during normal operation.

Occasionally, the detector's reaction chamber and sapphire window may require cleaning, refer to Section 5.7.

White crystal deposits on the windows of the reaction chamber and plugging of capillaries and vent are usually due to sample contaminates such as ammonia reacting with the high ozone levels and NO components. To eliminate the contaminates, the sampling system should be reworked or a preventive maintenance program developed (if dropout is not excessive).

Another source of crystalline formation is contaminated air.

Several components may require replacement. These are discussed in the following sections.

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Figure 5-2. uCEM Interconnect Diagram

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MAINTENANCE and SERVICE

5.2 Converter

Refer to Figure 5-1, Item 97, and Figure 5-3. To replace the converter or sensor, disconnect the two pneumatic tubes and two electrical connections.

Unlace the heater blanket, and remove the converter. Reassemble in reverse order, ensuring that the converter is oriented with the glass cloth at the bottom and the sensor is oriented correctly inside the heater jacket.

ASSEMBLED SIDE VIEW

Sensor

Heater

Jacket

655228

Converter

Tube 655227

Wrap with aluminum foil

Sensor

655282

Glass

Cloth

Figure 5-3. Converter Assembly

5.3 Ozonator

Refer to Figure 5-1, item 98.To replace the ozonator, remove the gas fittings, the two large straps and all tie-wraps, and disconnect the one electrical connection. Reassemble in reverse order.

5.4 Personality Modules

There are seven different personality modules. Depending on your unit, you may have three, four five, six, or seven modules installed. These personality modules are installed on a custom backplane. see figure 5-4 for more information.

Tag each cable and its location before disconnecting any wiring. This helps in re-assembly

To remove any on the personality modules. Remove cables from the module to be removed, there are two screws at the bottom of each module.

You will have to loosen each screw before you can remove the personality module.

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MAINTENANCE and SERVICE

Figure 5-4. Personality Modules and Backplane

.

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MAINTENANCE and SERVICE

5.5 Detector Assembly

Refer to Figure 5-5 and Figure 5-6.

R

EACTION

C

HAMBER

R

EMOVAL

:

Disconnect the stainless steel tubing lines at the Gyrolok fittings. Remove the (4) nuts holding the Detector Assembly to the chassis. Disconnect the plug from connector J1 on the Signal Board and remove the assembly from the chassis.

Note: Heatsink Compound. Care should be taken to avoid getting heatsink compound on optical surfaces. If this substance is removed during the disassembly process, a zinc-oxide-filled, silicone grease

(e.g., Dow Corning 340 or EG&G Wakefield Engineering's Series 120

Thermal Joint Compound) be reapplied in the re-assembly of this component.

Although the heater and thermostat can be removed to facilitate handling, contact with the white heatsink compound can be minimized by leaving these items in place. Remove the (2) screws holding the top plate of the

Detector , and move the plate along the wires and away from the Detector .

Remove the (2) screws holding the tube assembly in place. Hold the tubing with one hand while inverting the Detector Housing with the other, allowing the Reaction Chamber O-ring and window to be removed from below.

R

EACTION

C

HAMBER

I

NSTALLATION

:

To reinstall, hold the housing in the inverted position while sliding the

Reaction Chamber O-ring and window into position and the tubing into the slot in the housing. Hold the Reaction Chamber in place while rotating the housing upright. Replace the hold-down screws.

Note: Component Positioning. The procedure described above is for the purpose of maintaining the relative positions of windows and

O-ring to the Reaction Chamber during installation.

Replace the top cap and screws. Reverse the removal procedure to reinstall the Detector Assembly into the Analyzer Module.

P

HOTODIODE

R

EMOVAL

:

Remove the Detector Assembly as described above. Invert the housing to access the mounting bracket. Remove the (3) screws and shoulder

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-5

MAINTENANCE and SERVICE washers from the bracket. Remove the bracket, insulating disk and bottom plate as a unit to minimize the spread of the heatsink compound.

Remove the (2) screws holding the lower section of the Detector Housing, then slide the section along the cable and remove.

Remove the (2) screws holding the socket, thermistor and photodiode in place, being careful not to lose the washers that are used as shims.

Grasp the socket and photodiode base while slowly rotating to separate the photodiode from the housing. Some friction will be felt as an O-ring is used around the photodiode as a seal.

P

HOTODIODE

I

NSTALLATION

:

To replace the photodiode, carefully remove the diode from the green socket, and replace with a new one. Before mounting the new diode, the top cap of the enclosure should be temporarily removed and the (2) screws holding the Reaction Chamber loosened about two turns. This allows air which is trapped between the O-ring seals to escape when the diode is inserted. It also maintains the position of the O-ring and window in the upper compartment.

The new photodiode should be slowly inserted into the housing while gradually rotating the body. This allows the O-ring to properly seat.

Continue replacing screws, washers, thermistors, etc., with the thicker shim

(washer) on the opposite side of the socket from the thermistor.

Replace the lower section of the housing, then the bottom cover, insulator and bracket with the shoulder washers and screws.

Re-tighten the screws in the Reaction Chamber (upper section). Replace the top cap and its screws.

To reinstall in the Analyzer Module, reverse the procedure for removal as indicated above.

Photodiode

Sapphire

Window

Reaction

Chamber

Thermistor

Assembly

Sample

Ozone

Exhaust

Photodiode Socket

Assembly

Detector Mounting

Bracket

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-6

Heater

*

M3X0.5 x 16mm Screw (2)

3mm Spring Washer (2)

Heater

*

Thermostat

*

Tubing Cover

MAINTENANCE and SERVICE

M3X0.5 x 25mm Screw (2)

3mm Spring Washer (2)

Detector Header

Retainer Gasket

Reaction Chamber

O-Ring 854540

Sapphire Window

Cushioning Gasket

Photodiode

Cable

Insulator

(between Lower Cover and Mounting Bracket)

Photodiode Case

Ground

Lower Cover

Nylon Shoulder

Washers (3)

M3X0.5 x 16mm

Screw (3)

O-Ring 876478

Photodiode Assembly

(see detail below)

M3X0.5 x 20mm Screw (2)

3mm Spring Washer (2)

Detector Cover

M3X0.5 x 16mm Screw (2)

3mm Spring Washer (2)

*

Heater/Thermostat Assembly 655235.

Figure 5-6. Detector Assembly

Photodiode

655258

Thermistor

655216 Thermistor Spacer

Thermistor Shim

Photodiode Socket Assembly

No. 6 Flat Washer (2)

Assembly of Photodiode

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-7

MAINTENANCE and SERVICE

5.6 Central Processing Unit

The CPU is an Embedded Pentium-type AT Computer in 5.75” x 8” form factor. The peripherals integrated on board are: SVGA, 4 serial ports and one parallel port, Fast

Ethernet ctrl., IDE, Keyboard, Mouse, 2 USB. The module is built around the Intel

Tillamook processor and is equipped with 64MB SDRAM. The module also integrates one socket for SSD that performs like an HDD unit and can be used to store the operating system, the user’s programs and the data files. Other peripherals available on board are the Floppy disk controller, and the parallel port. The CPU is depicted in Figure

5-7.

Figure 5-7. CPU

5.6.1.1 Features

Architecture:

Dimensions:

Processor:

Memory:

PC/AT Compatible

5.75” x 8”

Intel Tillamook processor - 266MHz

64 MB SDRAM

Ram/Rom disk:

1 x 32 pin socket (max. 288MB)

Operating System:

WinNT

BIOS:

Interfaces:

Standard with embedded extensions

IDE ctrl

Floppy ctrl

SVGA-CRT

10/100 Mbps Fast Ethernet

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-8

MAINTENANCE and SERVICE

Bus:

Connectors:

Power Supply:

2 USB ports

4 RS232 serial ports (one can be 485)

Parallel port (bi-directional EPP-ECP)

Keyboard PS/2

Mouse PS/2

AT bus according to PC/104 spec.

AT/ATX

COM1-4, SVGA, USB 1 and 2, PS/2 Mouse/Keyboard,

ATX Power, Parallel, IDE, Floppy, and Fast Ethernet

5.6.1.2 EMBEDDED ENHANCED BIOS:

- Award, 256KB Flash Bios.The Bios is immediately activated when you first turn on the system. The Bios reads system configuratio information in CMOS RAM and begins the process of checking out the system.

5.6.2 Analog/Digital I/O Board

The Analog/Digital IO (ADIO) Board is an off-the-shelf, complete data acquisition system in a compact PC/104 packaging. The analog section contains 32 input channels, multiplexed A/D converter with 16 bit resolution and 10uS conversion time. Input ranges are +/-5v or +/- 10V. It also includes on-board DMA support. The analog output section includes two 12 bit D/A converters. Both sections features simplified calibration using on board programmable digital potentiometer. The digital I/O section provides 24 digital I/O lines, which feature high current TTL drivers. The board requires only +5V from the system power supply and generates its own +/-15V analog supplies on board. The board operates over the Extended Temperatures range of -25 to +85C. Figure 3 depicts the

ADIO board and Figure 5-9 depicts the ADIO block diagram.

Figure 3-8. ADIO Board

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-9

MAINTENANCE and SERVICE

Figure 5-9. ADIO Block Diagram

The ADIO board features automatic calibration of both analog inputs and outputs for enhanced accuracy and reliability. The potentiometers, which are subject to tampering and vibration, have been eliminated. Instead, all A/D calibration adjustments are performed using an octal 8-bit DAC. The DAC values are stored in an EEPROM and are recalled automatically on power up. The board includes three precision voltage references for negative full scale, zero, and positive full-scale. A calibration utility program provided with the board allows you to recalibrate the board anytime, in both unipolar and bipolar modes, and store the new settings in EEPROM.

Autocalibration applies to the 4 D/A channels as well. The full-scale D/A range is selected with a jumper block. The analog outputs are fed back to the A/D converter so they can be calibrated without user intervention. Again, calibration settings are stored in

EEPROM and automatically recalled on power-up.

The ADIO board provides split configuration capability, with more total input channels than any other PC/104 analog I/O board. The board can be user-configured in any of three ways:

Channels Format

32

24

16

32 single-ended

16 differential

8 differential, 16 single-ended

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-10

MAINTENANCE and SERVICE

5.6.2.3 Programmable Input Ranges

A programmable gain amplifier, programmable unipolar/bipolar range, and programmable 5V/10V full-scale range combine to give the ADIO board a total of 10 different possible analog input ranges. All range settings are controlled in software for maximum flexibility.

Mode Full-

Scale

Gain Input

Range

Resolution

Unipolar 10V 1 0-10V 0.153mV

Unipolar 5V 1 0-5V 0.076mV

Unipolar 5V 2 0-2.5V

0.038mV

Unipolar 5V 4 0-1.25V

0.019mV

Unipolar 5V 8 0-0.625V 0.0096mV

Bipolar 10V 1 ±10V 0.305mV

Bipolar 5V 1 ±5V 0.153mV

Bipolar 5V 2 ±2.5V

0.076mV

Bipolar 5V 4 ±1.25V

0.038mV

Bipolar 5V 8 ±0.625V

0.019mV

5.6.2.4 Enhanced Trigger and Sampling Control Signals

The ADIO board has an extra A/D trigger and sample control signals in the design.

Seven auxiliary digital I/O lines on the analog I/O connector provide a sample/hold output signal, A/D trigger in and out lines (to enable synchronization of multiple boards) and external A/D clocking.

The ADIO board contains 4 12-bit analog outputs with autocalibration capability. Up to

5mA of output current per channel can be drawn from all channels simultaneously. Both unipolar and bipolar output ranges are supported with jumper configuration. And on power up, all outputs are reset to 0V automatically.

Mode Full-Scale

Output

Range

Resolution

Unipolar 10V

Unipolar 5V

Bipolar

Bipolar

10V

5V

0-10V

0-5V

±10V

±5V

2.44mV

1.22mV

4.88mV

2.44mV

5.6.2.6 FIFO and 16-Bit Bus Interface

An on-board 1024-byte FIFO enables the ADIO board to work with Windows 95 and NT by dramatically reducing the interrupt overhead. Each interrupt transfers 256 2-byte samples, or half the buffer, so the interrupt rate is 1/256 the sample rate. FIFO operation

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-11

MAINTENANCE and SERVICE can be disabled at slow sample rates, so there is no lag time between sampling and data availability. The 16-bit interface further reduces software overhead by enabling all 16

A/D bits to be read in a single instruction, instead of requiring 2 8-bit read operations.

The net result of this streamlined design is that the ADIO board supports gap-free A/D sampling at rates up to 200,000 samples per second, twice as fast as our previous boards.

5.6.2.7 Specifications

Analog Inputs

Number of inputs

A/D resolution

Bipolar ranges

Unipolar ranges

Input bias current

Overvoltage protection

Nonlinearity

Conversion rate

On-board FIFO

Calibration

Analog Outputs

Number of outputs

D/A resolution

Output ranges

Output current

Settling time

Relative accuracy

Nonlinearity

Reset

Calibration

32 single-ended, 16 differential, or

16 SE + 8 DI; user selectable

16 bits (1/65,536 of full scale)

±10V, ±5V, ±2.5V, ±1.25V, ±0.625V

0-10V, 0-5V, 0-2.5V, 0-1.25V, 0-

.625V,

100pA max

±35V on any analog input without damage

±3LSB, no missing codes

200,000 samples/sec.max

1K x 8(512 16-bit samples)

Automatic;values stored in EEPROM

4

12 bits (1/4096 of full scale)

±5, ±10, 0-5, 0-10

±1 LSB

±5mA max per channel

6µS max to 0.01%

±1 LSB, monotonic

All channels reset to OV

Automatic; values stored in

EEPROM

Digital I/O

Main I/O

Input current

Output current

Logic 0

Logic 1

Auxilary I/O

24 programmable I/O

±1µA max

64mA max per line

-15mA max per line

4 inputs, 4 outputs, optional use as

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-12

MAINTENANCE and SERVICE trigger/control lines

Counter/Timers

A/D Pacer clock

Clock source

General purpose

General

Power supply

Operating temperature

Weight

32-bit down counter

(2 82C54 counters cascaded)

10MHz on-board clock or external signal

16-bit down counter (1 82C54 counter)

+5VD±10%@200mA typ

-25 to +85ƒC

3.4oz/96g

5.6.3 PCMCIA Adapter

The PCMCIA adapter supports Type I, II and III PCMCIA cards. The board is in full compliance with Microsoft FFS-II, PCMCIA V.2 and JEIDA 4.1 specifications. The

PCMCIA socket accepts The following PCMCIA cards:

Type I

Type II

Type III

Memory, Flash/SRAM/ROM

Fax, Modem, LAN, Wireless LAN, and SCSI

ATA mass storage

Figure 5-10. depicts the PCMCIA interface board.

Figure 5-10. PCMCIA Interface

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-13

MAINTENANCE and SERVICE

5.6.3.1 Features

Dimensions:

compliant with the PC/104 standard

- Compatible with AT PC/104 CPU modules

Functions on board:

2 PCMCIA slots

Optional remote socket

PCMCIA features

- Supports PCMCIA V.1.0 and V.2.0

- Supports PCMCIA types I, II and III

- Supports both I/O and Memory Card

- Supports Hot insertion

Operating Systems

- Dos and Windows and any other RTOS that supports PCMCIA.

Connectors

- J1 : PCMCIA 2 slots connector

- J3: PC/104 8 bit connector (XT compatible)

- J4 : PC/104 16 bit extension (AT extension compatible).

5.6.3.2 SOFTWARE FEATURES:

- Complete set of device drivers complying with PCMCIA V2.1 /JEIDA V4.1, running under MS-DOS or MS-WINDOWS: i) PCMCIA socket & card services drivers ii) Flash File System

- Software mappable memory windows and one I/O window

- Jumperless interrupt steering from PC Card to system.

5.6.4 Modem

The PC/104 Modular Modem™ is a self-contained modem module that provides the flexibility to include modem functionality into embedded system, with minimal engineering resources. The PC/104 Modular Modem™ is full featured including highspeed data and fax transmission. The PC/104 Modular Modems support both dial-up and 2-wire leased-line. Figure 5-11 depicts the Modem.

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-14

MAINTENANCE and SERVICE

Figure 5-11. Modem

5.6.4.1 Features

V.90, 56 kbps data (560PC/104)

V.34, 33.6 kbps data (336PC/104)

14.4 kbps fax

Voice playback and record

DTMF decode

-40 o

C to 85 o

C operation

3.775" x 3.550" x 0.568" (with modular phone jack)

3.775" x 3.550" x 0.435" (without modular phone jack)

8 bit PC/104 bus type

V.42 and MNP 2-4 error correction

V.42bis, and MNP-5 data compression

FCC Part 68 registered

FCC Part 15 compliant

2 wire leased-line and dial up support

Industry Canada CS-03 certified

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-15

MAINTENANCE and SERVICE

5.6.5 Flash Drive

Figure 5-12. 256MB Flash Drive.

5.6.5.1 Specifications

Start-up time

System Performance

*Notes 1 & 2

Start-up Time

Sleep to Write

Sleetp To Read

Reset to Ready

2.5 msec max.

2.5 msec max.

50 msec typical

400 msec max.

Data Transfer Rate to/from host

16.0 MB/sec burst

Active to Sleep Delay Programmable

Controller Overhead

Command to DRQ

<1.25 msec

Power Requirements

*Note 1

DC Input Voltage

Commercial

Industrial

3.3 V ± 5%, 5 V ± 10%

3.3 V ± 5%, 5 V ± 5%

Power Dissipation

(Notes 3 & 4)

@3.3 V @5.0 V

Read 35 mA RMS 50 mA RMS

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-1

MAINTENANCE and SERVICE

Write 35 mA RMS 50 mA RMS

Environmental

Specifications

Temperature:

Operating Commerical 0°C to 60°C

Operating Industrial -40°C to 85°C

Non-Operating

Commerical

-25°C to 85°C

Non-Operating

Industrial

-50°C to 100°C

Humidity:

Operating

Non-Operating

8% to 95%, non-condensing

8% to 95%, non-condensing

Acoustic Noise

Vibration:

Operating

Non-Operating

Shock:

Operating

Non-Operating

Altitude (relative to sea level)

Operating/Non-

Operating

0dB

15 G peak to peak max.

15 G peak to peak max.

1,000 G max.

1,000 G max.

80,000 feet max.

System Reliability and Maintenance

MTBF (Mean Time

Between Failures)

>1,000,000 hours

Preventive Maintenance None

Data Reliability <1 non-recoverable error in

10

(14)

bits read

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-2

MAINTENANCE and SERVICE

Physical

Specifications

Length

Width

100.2mm ± 0.51mm

69.85mm ± 0.51mm

9.6mm ± 5.0mm

Thickness (Body)

Thickness

(Removable Edge)

Weight

N/A

160 g. max

Note 1: All values quoted are typical at ambient temperature and nominal supply voltage unless otherwise stated.

Note 2: All performance timing assumes the controller is in the default (i.e., fastest) mode.

Note 3: Sleep mode currently is specified under the condition that all card inputs are static CMOS levels and in a "Not Busy" operating state.

Note 4: The currents specified show the bounds of programmability of the product.

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-3

MAINTENANCE and SERVICE

5.6.6 Pocket PC

The Pocket PC acts as an Graphic User Interface to the

µ

CEM unit. Figure 5-13 depicts the Pocket PC.

Figure 5-13. Pocket PC

Following are the Pocket PC specifications:

Processor

Memory

Display

User Interface

206MHz StrongArm processor

32MB RAM, 32MB ROM

240 x 320 pixels LCD, TFT color CSTN, backlit

Pen-and-touch interface (stylus included)

Power

4 user-configurable quick launch screen icons

2 quick keys (Record and Scroll/Action)

Built-in Lithium-Ion rechargeable battery

8 hours of battery life 1

Input/Output

IrDA infrared port

RS232 port

USB port

CompactFlash Type I card slot

Sound

Audio speaker and microphone

Digital compatible

Other Standard

USB

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-1

MAINTENANCE and SERVICE

Features

Serial

Earphones

Removable cover

Physical

Specifications

Operating

Requirements

5.2 × 3.1 × 0.6 in (13 × 7.8 × 1.6 cm)

9.1 oz (260 g) with battery

Operating temperature: 32–104° F (0–40° C)

Storage temperature: 32–140° F (0–60° C)

Humidity: 90% relative humidity at 104° F (40° C)

5.6.7 Wireless LAN Adapter

Wireless LAN adapter is an option to allow the user to remove the Pocket PC from the enclosure and to operate the

µ

CEM from a distance up to 1000 feet. Figure 5-14 depicts the wireless LAN adapter.

Figure 5-14. Wireless LAN adapter

Following is a technical description of the wireless LAN adapter.

Data Rate:

Useful Range:

11 Mbps send/receive with automatic fallback for extended range

Up to 1000 feet (300 meters) open field; 300 feet (90 meters) typical indoor installations (intervening metal and thick concrete structures degrade performance and range)

Security:

Supports Wired Equivalent Privacy (WEP) which provides 64-bit and 128bit data encryption; additional security through the use of a 32-character network system ID

Standard Support:

Interoperable with 2 Mbps IEEE 802.11 Direct Sequence Spread

OS Support:

Channels:

Spectrum (DSSS) and 802.11b (11 and 5.5 Mbps) extension

NDIS drivers included for Windows 95, 98, ME and NT and 2000

Supports 11 US/Canada and 13 ETSI selectable, fully-independent channels

Transmit Power:

25mW typical

Radio Frequency:

2.4 to 2.4835 GHz

Power Requirement:

PC Card: 5 VDC @ 217 mA average with 338 mA maximum on transmit;

215 mA continuous receive, 17 mA standby

PCI: 5VDC @ 247 mA average with 368 mA maximum on transmit; 245

Status lights:

mA continuous receive, 47 mA standby

1 (Reports: Link, Power)

Regulatory Approval:

US - FCC part 15B and 15C, IC RSS-210

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-2

MAINTENANCE and SERVICE

Physical

Specification:

Antenna(s):

ETSI - FCC part 15B, CE, ETS 300 328, ETS 300 826, C-Tick (Australia)

PC Card: PCMCIA Type II PC Card

PCI: 32-bit, 5V Key, Full Plug-N-Play

Integrated: Printed dual diversity

External: 2.2dBi dipole; additional options for specific installation needs

5.6.8 500 Watts Power Supply

The 500 Watts power supply combine high performance midrange power with high power density (4.4 watts/in

3

),active Power Factor Correction (PFC) and high reliability to meet the requirements of commercial and industrial systems. Providing tightly regulated DC power, the power supply delivers full output performance with only 300

Linear Feet per Minute (LFM) forced air-cooling by utilizing a factory installed fan. Other features include remote sense, power fail, logic level inhibit, DC power good. Main channel current sharing is provided for redundant applications. The power supply is approved to the latest international regulatory standards, and displays the CE Mark.

Figure 5-15. 500 Watts Power Supply

5.6.8.1 FEATURES

• Power Factor Correction (PFC) Meets EN61000-3-2

• Fully Regulated Outputs

• Remote Sense

• Current Share, Power Fail, and Power Good Signals

• Overtemperature, Overvoltage, and Overcurrent Protected

• Available with Metric or SAE Mountings

• Input Transient & ESD Compliance to EN61000-4-2/-3/-4/-5

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-3

MAINTENANCE and SERVICE

• Fan Output Voltage and Optional Fan

• Optional Isolation Diodes for Parallel or Redundant Operation

5.7 Replacement Parts

WARNING: PARTS INTEGRITY

Tampering with or unauthorized substitution of components may adversely affect the safety of this product. Use only factory approved components for repair.

5.7.1 Replacement Part list

The following is a list of replacement parts for the uCEM analyzer. For other parts or service, contact the factory as indicated in session 6.

Figure 5-4. uCEM Analyzer with door open – Front View

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-4

MAINTENANCE and SERVICE

17 CSTS

18

19 CSTS

20 CSTS

21 CSTS

22

23 CSTS

24 CSTS

25 CSTS

26 CSTS

27 CSTS

28 CSTS

29 CSTS

30 CSTS

31 CSTS

32 CSTS

33 CSTS

34 CSTS

35 CSTS

36 CSTS

37 CSTS

38 CSTS

39 CSTS

40 CSTS

41 CSTS

Item

1 CSTS

2 CSTS

3 CSTS

4 CSTS

5 CSTS

Vendor

6 CSTS

7 CSTS

8 CSTS

9 CSTS

10 CSTS

11 CSTS

12 CSTS

13 CSTS

14 CSTS

15 CSTS

16 CSTS

PARTS LIST

1020883-100

1020999-100

1021014-100

1021116-100

1020889-101

1020890-100

1020891-100

1020892-100

1020893-100

1020894-100

1020895-100

1020896-100

1020897-100

1020898-100

1020899-100

1020900-100

1020901-100

1020902-100

1021168-100

1020904-100

1021090-100

1021160-100

1020907-100

Mfg. Part Number

1020968-100

1020113-102

1020839-101

1020840-100

1020841-102

1020842-102

1020843-101

1021109-101

1021146-100

1021146-100

1021108-100

1021114-101

1020876-101

1021099-100

1020877-101

1020878-100

Description

Assy, Power Supply

Flow Diagram

Assy, PMD Module

Assy, NDIR Module

Assy, PDD Module

Assy, AUX Module

Assy, EXIO Module

Assy, Backplane, Electronic Modules, T/S

Assy, EAIO Module

Assy, EDIO Module

Assy, MLT-IR UV Module

Cable Assy, EXT I/O interface, Internal

Assy, Cable, AC Power Distribution

Assy, Cable, +24V Power to Bckplane, SO2

Assy, Cable, +24V Power to Backplane

Assy, Cable, SBC Power from Backplane

Assy, Cable, LAN

Assy, Cable, Heartbeat LED

Assy, Cable, Trouble LED

Assy, Cable, Serial, RS232/485, Intenal

Cable Assy, IDE Drive

Cable Assy, Analog I/O, Ribbon

Cable Assy, Digital I/O, Ribbon

Cable Assy, Detector Signal, PMD

Cable Assy, NDIR Stepping Motor

Cable Assy, NDIR Light Barrier

Cable Assy, Thermister, PMD

Cable Assy, NDIR Light Source

Cable Assy, PDD Petier

Cable Assy, PDD, Heater Temperature

Cable Assy, PDD, Heater Power

Cable Assy, Converter Power

Cable Assy, Converter Temperature

Cable Assy, Ozonator Power

Cable Assy, TE Cooler Power/Control

Cable Assy, System Heartbeat Indicator

Cable Assy, ELECTRO/CHEMICAL, THERMISTOR

Assy, TE Cooler, 14 Modules

Cable Assy, Zone Temperature, Internal, External

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-5

MAINTENANCE and SERVICE

42 CSTS

43

44 CSTS

45 CSTS

46 CSTS

47 CSTS

48 CSTS

49 CSTS

50 CSTS

51 CSTS

52 CSTS

53 CSTS

54 CSTS

55

56 CSTS

57 CSTS

58 CSTS

59 CSTS

60 CSTS

61

62 CSTS

63 CSTS

64 CSTS

65 CSTS

66 CSTS

31531

31353

31355

31356

31367

31502

31532

31270

31281

1020908-100

1021115-100

31503

31334

31338

31530

31528

31529

31283

31284

31285

31286

31287

Cable Assy, Gas Valve Control

Cable Assy, SHU#1 I/O

CHASSIS, Top, INTERNAL, uCEM

INSULATOR, POCKET PC

BRACKET, MOUNTING, REGULATOR

ENCLOSURE, MODIFIED, FIBERGLASS

SHELF, OVEN, SLIDING

COVER, INTERNAL, uCEM

OVERLAY, CONNECTOR PANEL

BKT, FLOWMETER/GAUGE

GUIDE, SHELF, LEFT

GUIDE, SHELF, RIGHT

PANEL, BREAKER/RS232, Ucem

CHASSIS, REAR, INTERNAL, uCEM

PLATE, MOUNTING, CONNECTOR, I/O

PLATE, MOUNTING, BH, FEED THRU

BRACKET, MOUNTING, CONVERTER

BRACKET, MTG, POCKET PC, LEFT

BRACKET, MTG, POCKET PC, RIGHT

FRAME, GLASS, ENCLOSURE

GLASS, WINDOW, ENCLOSURE DOOR

GASKET, WINDOW

67 CSTS

68 CSTS

69 CSTS

70 RMT-GMBH

71 RMT-GMBH

72 RMT-GMBH

73 RMT-GMBH

31289

31290

31299

42711801

42714157

42715604

90003311

GASKET, CONNECTOR PANEL

GASKET, GAS PORT PANEL

PLATE, MOUNTING, 2.5 HARD DRIVE

Cable, Electrical

ElectroChemical Detector

NDIR Detector

Paramagnetic Detector, Insulated

74 RMT-GMBH

75 SNAP-TITE

76 SNAP-TITE

77 SNAP-TITE

78 DWYER INST.

79

100-900-472-04

Any MPT-1/8 CRES

Cable, Electrical (Paramagnetic Detector

Manifold, 4port

2W1.3W-5DR-E2.46 2 way Valve

3W16W-1NR--V2A6 3 way Valve

RMA-14SSV Flowmeter

1/8 mpt, Plug

80 HOKE/SWAGELOC

2CM2-316/SS-200-1-2

81 HOKE/SWAGELOC

4LM4-316/SS-400-2-4

1/8 mpt x 1/8t, Fitting

1/4mpt x 1/4t 90 deg El

82

HOKE/SWAGELOC

4BU-316/SS-400-61 1/4 x 1/4t Bulkhead Coupling, SS

83

CRAWFORD/SWGLO

B-400-61-2 1/4 x 1/8t Bulkhead Coupling,brass

84

HOKE/SWAGELOC

2TTT-316/SS-200-3 1/8t "Tee"

85 HOKE/SWAGELOC 2CF2/B-200-7-2

86 INSOL.SUPPLY 31413

87 INSOL.SUPPLY 31415

88 INSOL.SUPPLY 31414

1/8t x 1/8fpt Coupling, brass

1/8 inch tubing

1/4 inch tubing

1/8 inch black tubing

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-6

MAINTENANCE and SERVICE

89 Westam Rubber 31412

90 RMT-GMBH 337489

91

Sante Fe Rub. Prod.

632784

92 RAI 634398

93

Marshal Town Mfg. Or

Marsh Inst. Co.

1/4 inch tubing, Viton

Desicannt Bulbs

1/4glass x 1/8t, Grommet

Capillary, Vent

94 CSTS

95 RAI

1020973-100

655250

96 SWAGELOC

97 RAI

98 Te Lite

99 RAI

SS-0RM2

657716

657719

658157

100 RAI 659754

101

HOKE/SWAGELOC

2TMT2-316/SS-200-3TMT

Assy, Cable,Thermistor

Converter

Trim Valve, 1/8 male NPT

Power Supply-Ozonator

Ozone Generator

Restrictor, brass

Photo Diode Detector

1/8MPT X 1/8t MALE RUN TEE

102

HOKE/SWAGELOC

2TMT4-316/SS-3-4TMT

1/4MPT X 1/8t MALE RUN TEE

103

HOKE/SWAGELOC 2R4-316/SS-200-R-4

Reducer

104

HOKE/SWAGELOC

2LU-316/SS-200-9 90 deg El (used with PDD)

105

HOKE/SWAGELOC 2CF2-316/SS-200-7-2

1/8FPT X 1/8t

106

107

ANY1/4" CRES 10-32 Set screw, CRES

Spring (Converter)

108

HOKE/SWAGELOC

4BRU2-316/SS-400-61-2

1/4 x 1/8t Bulkhead Coupling, SS

109

HOKE/SWAGELOC 4PC-316/SS-401-PC

Fitting, 1/4 inch connector tube

110 CLIC

111 JACO

CLIC-47

70-2KO

Clamp

1/8t "Tee" Kynar

112

SIEMENS-MOORE or

MOORE PROD. CO

12023-47 or BM-12023-

47/3VJ

Regulator

113 HOKE

114 NUMATIC

115 HOKE

116

117

118 CRYDOM

119

120 CSTS

4R2-316

SF-062-SS

4C-316

M4 x 0.5 x 16mm

D1D12

1021118-100

121 CSTS

122 CSTS

123 KAD

124 CSTS

1021121-100

1021122-100

M3 X 6mm

1021143-100

125 CSTS

126 CSTS

1020996-100

1020997-100

127 CSTS 1020998-100

128 World Magnetics 9032-904

129 McMaster-Carr 30345T4

130 COMM CON

131 CSTS

132 COMM CON

133 COMM CON

HW-PC440NP

31298

HW-PC440SP

HW-PC600P

1/8 to 1/4 Adapter Fitting

1/8t (barb) x 10-32w/seal Fitting

1/4t CROSS

Screw, M4 x 0.5 x 16mm

RELAY, POWER, 12 AMPS

Cable Assy, CPU I/O

Cable Assy, SSU POWER, External, 6’

Cable Assy, CPU I/O, External, 6'

Screw, PHP, M3 x 6mm

DRIVE, FLASH, 256MB, REV. B1.3

Cable Assy, Heater, PMD

Cable Assy, Detector Signal, NDIR

Cable Assy, Thermister, NDIR

Pressure Switch, PSF103, Barb conn

LANYARD, 12 INCH, 304 SS, EYE ENDS

NUT, 4-40, NYLON

SPACER, PC104

SCREW, 4-40 X .18, NYLON

SPACER, PC104, NYLON

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-7

MAINTENANCE and SERVICE

MS24693-C3B

MS24693-C25B

MS51957-26

MS51957-28

MS51957-30

MS51957-

MS51957-37

MS51957-47

MS51957-15

MS15795-807

MS35338-135

MS35338-136

MS35338-137

MS35338-138

NAS671C8

MS51957-63

MS51957-64

MS51957-65

FSSI-22

MS24693-C25

4926

31391-5

31391-6

31391-7

31391-8

1020976-101

1020977-100

1021119-100

1021120-100

1020984-100

31354

31376-01

31376-02

31376-03

31376-04

31376-05

FSSI-8

FSSI-10

FSSI-12

FSSI-14

FSSI-16

10-101949-08

10-101949-10

10-101949-12

10-101949-14

10-101949-16

134 CSTS

135 CSTS

136 CSTS

137 CSTS

138 CSTS

139 CSTS

140 CSTS

141 CSTS

142 CSTS

143 CSTS

144 CSTS

145 Fastener Spec.

146 Fastener Spec.

147 Fastener Spec.

148 Fastener Spec.

149 Fastener Spec.

150 Amphenol (TTI)

151 Amphenol (TTI)

152 Amphenol (TTI)

153 Amphenol (TTI)

154 Amphenol (TTI)

155 KAD

156 KAD

157 KAD

158 KAD

159 KAD

160 KAD

161 KAD

162 KAD

163 KAD

164 KAD

165 KAD

166 KAD

167 KAD

168 KAD

169 KAD

170 KAD

171 KAD

172 KAD

173 Fastener Spec.

174 KAD

175 3M

176

177 CSTS

178 CSTS

179 CSTS

180 CSTS

ASSY, CPU, PC104

ASSY, I/0, PC104

Cable Assy, EXT I/O Interface, External, 6'

Cable Assy, SHU Interface, External, 6'

Cable Assy, AC Power, 110VAC, Ext, 6'

Clamp, Cable, Fiber Optic

Cover, Connector Opening, .594

Cover, Connector Opening, .719

Cover, Connector Opening, .812

Cover, Connector Opening, .906

Cover, Connector Opening, .969

Plate, Nut, .594

Plate, Nut, .719

Plate, Nut, .812

Plate, Nut, .906

Plate, Nut, .969

Gasket, Connector, Shell Size 8

Gasket, Connector, Shell Size 10

Gasket, Connector, Shell Size 12

Gasket, Connector, Shell Size 14

Gasket, Connector, Shell Size 16

Screw, FHP, 4-40 X .312, Black

Screw, FHP, 6-32 X .312, Black

Screw, PHP, 6-32 x .25

Screw, PHP, 6-32 x .38

Screw, PHP, 6-32 x .50

Screw, PHP, 6-32 x

Screw, PHP, 6-32 x 1.75

Screw, PHP, 8-32 x .75

Screw, PHP, 4-40 x .38

Washer, Flat, #8

Washer, Split Lock, #4

Washer, Split Lock, #6

Washer, Split Lock, #8

Washer, Split Lock, #10

NUT, HEX, 8-32

Screw, PHP, 10-32 x .50

Screw, PHP, 10-32 x .62

Screw, PHP, 10-32 x .75

Plate, Nut, 1.375

Screw, FHP, 6-32 X .312

Tape, VHB, Double sided, .015 x 1.0

Insulation, Enclosure

Insulation, Enclosure

Insulation, Enclosure

Insulation, Enclosure

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-8

MAINTENANCE and SERVICE

181 CSTS

182 CSTS

183 CSTS

184 CSTS

185 CSTS

186 CSTS

187 RICHCO

188 RICHCO

189 CSTS

190

191 CSTS

192 CSTS

193 CSTS

194 EAR

195 CLIC

196 RMT-GMBH

197 E-T-A

198 Amphenol (TTI)

31391-9

31391-10

31391-11

31391-12

31391-1

31391-4

BHKL350-4-01

BHKL750-4-01

1020973-102

31504

31508

31508

G-411-1

CLIC-43

TBD

3130-F212-P7T1-S120

10-202949-22

Insulation, Enclosure

Insulation, Enclosure

Insulation, Enclosure

Insulation, Enclosure

Insulation, Enclosure

Insulation, Enclosure

Blind Hole Kurly-Lok, .30-.40 dia bundle

Blind Hole Kurly-Lok, .70-.80 dia bundle

Cable Assy, CO Detector Thermistor

Cover, SO2 Detector, Long

Insulator, Mounting, PS, UV Detector

Bracket, Mounting, SO2 Detector

Grommet, Damping

Clamp, 1IN ID

DETECTOR, SO2

CIRCUIT BREAKER

GASKET, CONNECTOR, SHELL SIZE 22

Table 5-2. Replacement Part List

5.8 System Enclosure

The µCEM is enclosed in a rugged fiberglass enclosure. The enclosure is self contained and has the following approximate weight and dimensions:

Construction:

Dimensions:

Fiberglass, with environmentally sealed access door

24” x 20” x 8”

Weight: ~68Lbs

Figure 5.16 Illustrate the systems enclosures with all of the physical components layout.

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-9

MAINTENANCE and SERVICE

Figure 5-16. µCEM Enclosure with door open.

5.9 Trouble LED

The Red Trouble LED output is activated whenever there is a critical alarm that has not been acknowledged and adjusted.

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

5-10

SOFTWARE

6.

µ

CEM Software

The

µ

CEM Software includes 3 main components. One component is the

µ

CEM control software that interfaces with the instrumentation and records the emissions measurements. A second component is the User Interface Software that provides realtime status and configuration dialogs. A third component is the web server software that uses VB Script or Java Script to provide a web-based interface to the

µ

CEM.

6.1

µ

CEM User Interface Software

Hardware Platform

Pocket PC

The

µ

CEM User Interface Software communicates with the

µ

CEM Control Software using TCP/IP. It may run locally on the

µ

CEM computer or remotely on a Pocket PC with a RS232 connection to the

µ

CEM computer. It will not normally run locally since there is no input device or display connected to the

µ

CEM processor.

6.2

µ

CEM Web Server Software

Web Browser

Requires Internet Explorer 4.0 or Netscape 4.0

The Web Server Software provides the web based interface described in this document.

It is implemented as a VB Script or Java Script. The script will obtain much of the needed information directly from the Data-Log files or configuration file. The real-time information will be obtained from a memory segment shared with the

µ

CEM control software. The web server support multiple simultaneous clients. The maximum number of allowed connections could be limited to a reasonable number through the Windows

CE Web Server configuration dialogs.

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

6-1

SOFTWARE

uCEM User

Interface

Pocket PC

Serial

Cable

uCEM Computer

TCP/IP

uCEM

Control

Software

HTML (TCP/

IP)

Shared

Memory

Segment

Device Drivers

Data-Log

& Config

Files

As an option a

Wireless Network may be used.

Digital and

Analog IO

Web

Server

Script

HTML

Workstation

Ethernet,

Modem or serial

Sensors and

Control Circuitry

Figure 6-1 -

µ

CEM Software Block Diagram

6.3 Software Development Management

Microsoft Visual SorceSafe is used for version control of all of the

µ

CEM software.

Compuware’s Track Record is used for change request management and defect tracking.

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

6-2

SOFTWARE

6.4

µ

CEM Pocket PC Connection Failure

In the event of the connection with the

µ

CEM failed, a connection failure dialog will be displayed. It will display the following message.

Connection with

µ

CEM Lost, Retrying…

A Cancel button will be displayed. The

µ

CEM software will continue to attempt to reconnect with the

µ

CEM indefinitely and will stop when a connection is made or the cancel button is pressed.

If the Cancel button is pressed, any setting changes that were made without pressing

OK to accept will be lost. If Auto Calibration was in process, it will be completed by the

µ

CEM even though the connection was lost.

Rosemount Analytical

µ

CEM

Continuous Analyzer Transmitter

6-3

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