Rosemount CAT 100-Rev D Owner's manual

Instruction Manual

748441-D

May 2004

http://www.processanalytic.com

Model CAT 100

Continuous Analyzer Transmitter

Emerson Process Management

Manufacturing GmbH & Co. OHG

Industriestrasse 1

D-63594 Hasselroth

T +49(6055) 884-0

F +49(6055) 884-209

http://www.emersonprocess.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and in-

ternational standards. Because these instruments are sophisticated technical products, you

MUST properly install, use, and maintain them

to ensure they continue to operate within their

normal specifications. The following instructions MUST be adhered to

and integrated into your

safety program when installing, using, and maintaining Rosemount Analytical products. Failure to

follow the proper instructions may cause any one of the following situations to occur: Loss of life;

personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions

prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Rosemount Analytical repre-

sentative for clarification.

•

Follow all warnings, cautions, and instructions

marked on and supplied with the product.

•

Inform and educate your personnel in the proper installation, operation, and mainte-

nance of the product.

•

Install your equipment as specified in the Installation Instructions of the appropriate In-

struction Manual and per applicable local and national codes. Connect all products to the

proper electrical and pressure sources.

•

To ensure proper performance, use qualified personnel

to install, operate, update, program,

and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts

specified by Rosemount. Unauthorized parts and procedures can affect the product’s per-

formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY

.

Look-alike substitutions may result in fire, electrical hazards, or improper operation.

•

Ensure that all equipment doors are closed and protective covers are in place, except

when maintenance is being performed by qualified persons, to prevent electrical shock

and personal injury.

The information contained in this document is subject to change without notice.

Teflon® and Viton® are registered trademarks of E. I. duPont de Nemours and Co., Inc.

SNOOP® is a registered trademark of NUPRO Co.

1

st

Edition 04/2002 2

nd

Edition: 05/2004

Instruction Manual

748441-D

April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Contents i

Model CAT 100

TABLE OF CONTENTS

PREFACE...........................................................................................................................................P-1

Definitions...........................................................................................................................................P-1

Intended Use Statement.....................................................................................................................P-2

Safety Summary.................................................................................................................................P-2

General Precautions For Handling And Storing High Pressure Gas Cylinders .................................P-5

Documentation....................................................................................................................................P-6

Compliances.......................................................................................................................................P-6

1.0 DESCRIPTION AND SPECIFICATIONS..............................................................................1-1

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

1-2 Typical Applications...............................................................................................................1-1

1-3 Detector Methodologies.........................................................................................................1-2

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

b. Paramagnetic Oxygen Method .......................................................................................1-6

c. Electrochemical Oxygen Method....................................................................................1-7

d. Thermal Conductivity Method.........................................................................................1-9

1-4 Specifications.........................................................................................................................1-11

a. General ...........................................................................................................................1-11

b. CAT 100 Detector ...........................................................................................................1-12

2.0 INSTALLATION ....................................................................................................................2-1

2-1 Process and Calibration Gas Connection .............................................................................2-1

a. Gas Conditioning.............................................................................................................2-5

2-2 Installation..............................................................................................................................2-6

a. Location...........................................................................................................................2-6

b. Limitations.......................................................................................................................2-6

c. Gas Lines........................................................................................................................2-6

d. Services ..........................................................................................................................2-6

e. Mounting Options............................................................................................................2-6

f. Vent Lines.......................................................................................................................2-6

g. Electrical Connections ....................................................................................................2-7

2-3 Analytical Leak Check...........................................................................................................2-11

a. Flow Indicator Method.....................................................................................................2-11

b. Manometer Method.........................................................................................................2-12

3.0 OPERATION .........................................................................................................................3-1

3-1 Startup Procedure .................................................................................................................3-1

3-2 Touchpad...............................................................................................................................3-1

a. Overview.........................................................................................................................3-1

b. Elements.........................................................................................................................3-1

c. Actuator Tool...................................................................................................................3-2

d. Operation ........................................................................................................................3-2

e. Functions.........................................................................................................................3-3

f. FUNCTION Touchpad ....................................................................................................3-4

g. ENTER Touchpad...........................................................................................................3-5

h. INPUT-CONTROL Touchpads........................................................................................3-5

Instruction Manual

748441-D

April 2002

ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

3-3 Entry of System Parameters..................................................................................................3-7

A. Pressure Correction........................................................................................................3-7

b. Cross Compensation ......................................................................................................3-7

c. Cross Compensation Calibration....................................................................................3-7

d. Hold.................................................................................................................................3-8

e. Automatic Calibration......................................................................................................3-8

f. Tolerance Check.............................................................................................................3-8

g. Display Off.......................................................................................................................3-9

h. Analog Signal Outputs....................................................................................................3-9

i. Flushing Period...............................................................................................................3-9

j. User Code.......................................................................................................................3-9

k. Response Time...............................................................................................................3-10

l. Offset Value ....................................................................................................................3-10

m. Range Value ...................................................................................................................3-10

n. Reset...............................................................................................................................3-10

o. Program Version.............................................................................................................3-11

p. Serial Number.................................................................................................................3-11

q. Pump...............................................................................................................................3-11

3-4 Calibration..............................................................................................................................3-12

a. Zeroing............................................................................................................................3-12

b. Spanning.........................................................................................................................3-12

3-5 Manual Calibration.................................................................................................................3-13

a. Zeroing............................................................................................................................3-13

b. Spanning.........................................................................................................................3-13

3-6 Automatic Calibration (Option) ..............................................................................................3-15

a. Zeroing............................................................................................................................3-15

b. Combined Zeroing and Spanning...................................................................................3-15

3-7 Concentration Limits..............................................................................................................3-16

3-8 Measurement.........................................................................................................................3-17

3-9 Shut Down.............................................................................................................................3-18

3-10 Temperature Stabilization (option)........................................................................................3-19

a. Changing Temperature Settings.....................................................................................3-19

b. Controller Settings...........................................................................................................3-20

4.0 SERIAL INTERFACE OPTION.............................................................................................4-1

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

4-2 Protocols................................................................................................................................4-2

a. RS 232............................................................................................................................4-2

b. RS 485............................................................................................................................4-2

4-3 Setting Interface Parameters.................................................................................................4-3

a. ON/OFF Status ...............................................................................................................4-3

b. Communication Parameters ...........................................................................................4-3

4-4 String Syntax .........................................................................................................................4-4

a. Status Strings..................................................................................................................4-5

b. Numerical Representations.............................................................................................4-6

c. Block Parity Check..........................................................................................................4-6

4-5 Instruction (Receive) Syntax..................................................................................................4-7

a. Instruction Listing............................................................................................................4-7

b. Response String Syntax .................................................................................................4-8

Instruction Manual

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April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii

Model CAT 100

5.0 MAINTENANCE AND SERVICE ..........................................................................................5-1

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

a. Operating Factors ...........................................................................................................5-1

b. Analyzer Replacement....................................................................................................5-1

c. Analyzer Repair...............................................................................................................5-1

5-2 Component Removal.............................................................................................................5-2

a. Analyzer Removal...........................................................................................................5-3

b. Analyzer Replacement....................................................................................................5-3

c. Power Supply Assembly Removal..................................................................................5-3

5-3 Analyzer Configuration and Adjustment................................................................................5-4

a. Component Layout..........................................................................................................5-4

b. Photometer Assembly.....................................................................................................5-9

c. Analyzer Rear Panel.......................................................................................................5-12

d. Thermal Conductivity Response Time............................................................................5-14

5-4 Maintenance..........................................................................................................................5-16

a. Routine and Preventive...................................................................................................5-16

b. Checking and Cleaning of the Analyzer..........................................................................5-16

c. Cleaning and Replacement of Photometric Components...............................................5-17

d. Light Source Replacement..............................................................................................5-18

e. Removal of Analysis Cells ..............................................................................................5-19

f. Cleaning of Analysis Cells and Windows........................................................................5-20

g. Reinstalling Analysis Cells..............................................................................................5-20

h. Reinstalling Photometer Assembly.................................................................................5-20

i. Physical Zeroing..............................................................................................................5-20

j. Replacement of Electrochemical Oxygen Sensor ..........................................................5-21

k. Check of the Sensor........................................................................................................5-22

l. Removal of the Sensor ...................................................................................................5-23

m. Basic Calibration for the Oxygen Sensor........................................................................5-27

n. Sample Pump Maintenance............................................................................................5-27

o. Replacing the EPROM....................................................................................................5-28

5-5 Analyzer Service....................................................................................................................5-29

a. Test Points for BKS PC Board........................................................................................5-29

b. Test Points for OXS PC Board........................................................................................5-35

c. Power Supply..................................................................................................................5-37

6.0 TROUBLESHOOTING..........................................................................................................6-1

6-1 Error Messages .....................................................................................................................6-1

6-2 Troubleshooting Leaks..........................................................................................................6-6

7.0 RETURN OF MATERIAL....................................................................................................7-1

7-1 Return Of Material.................................................................................................................7-1

7-2 Customer Service..................................................................................................................7-1

7-3 Training..................................................................................................................................7-1

8.0 INDEX....................................................................................................................................8-1

Instruction Manual

748441-D

April 2002

iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

LIST OF ILLUSTRATIONS

Figure 1-1. Absorption Bands of Sample Gas and Transmittance of Interference Filters ...... 1-3

Figure 1-2. Opto-Pneumatic Gas Detector............................................................................... 1-4

Figure 1-3. Overall NDIR Method............................................................................................. 1-5

Figure 1-4. Paramagnetic Oxygen Analysis............................................................................. 1-6

Figure 1-5. Electrochemical Oxygen Sensor............................................................................ 1-7

Figure 1-6. Reaction of Galvanic Cell ...................................................................................... 1-8

Figure 1-7. Thermal Conductivity Sensor................................................................................. 1-9

Figure 1-8. Response Time vs Flow Rate Dependence........................................................ 1-10

Figure 2-1. Gas Connections................................................................................................... 2-2

Figure 2-2. Piping Diagram (Two channel series).................................................................... 2-3

Figure 2-3. CAT 100 Outline and Mounting Dimensions ......................................................... 2-4

Figure 2-4. Increased Safety Junction Box Terminals........................................................... 2-10

Figure 2-5. Leak check - Flow Indicator Method.................................................................... 2-11

Figure 2-6. Leak Check - Manometer Method .......................................................................2-12

Figure 3-1. CAT 100 Touchpad................................................................................................3-1

Figure 3-2. Touchpad Actuator Tool PN 42715575 ................................................................. 3-2

Figure 3-3. Storing The Actuator Tool...................................................................................... 3-2

Figure 3-4. Touchpad Operation.............................................................................................. 3-3

Figure 3-5. CAT 100 Analyzer Touchpad Function Identification............................................ 3-3

Figure 3-6. CAT 100 Touchpad Functions............................................................................... 3-4

Figure 3-7. Analyzer Operating Function Matrix ..................................................................... 3-6

Figure 3-8. Temperature Controller....................................................................................... 3-19

Figure 5-1. CAT 100 Enclosure Assembly............................................................................... 5-2

Figure 5-2. Analyzer Component Layout (Infrared Channel / Oxygen Measurement,

Combined) ............................................................................................................. 5-5

Figure 5-3. Analyzer Component Layout (1 Channel Oxygen Measurement,

Electrochemical)....................................................................................................5-6

Figure 5-4. Analyzer Component Layout (Paramagnetic Oxygen Measurement / Thermal

Conductivity, Combined)........................................................................................ 5-7

Figure 5-5. Analyzer Component Layout (Infrared Channel / Thermal Conductivity,

Combined) ............................................................................................................. 5-8

Figure 5-6. Photometer Assembly with Pyroelectrical Detector............................................. 5-10

Figure 5-7. Photometer Assembly with Gas Detector............................................................ 5-11

Figure 5-8. Analyzer Rear Panel Layout................................................................................5-12

Figure 5-9. Pin Assignments (View Looking At Rear Panel).................................................. 5-13

Figure 5-10. TC Sensor Short Response Time Setting (Standard) .........................................5-15

Figure 5-11. TC Sensor Long Response Time Setting............................................................ 5-15

Figure 5-12. Analyzer Photometer Assembly ( 2 Channel Infrared Analyzer, Viewed From

Front Panel Side)................................................................................................. 5-17

Figure 5-13. Photometer Assembly..........................................................................................5-19

Figure 5-14. OXS PCB Measuring Points............................................................................... 5-22

Figure 5-15. Oxygen Sensor without Infrared Channel........................................................... 5-23

Figure 5-16. OXS PCB Connector P2..................................................................................... 5-24

Figure 5-17. Oxygen Sensor Support (Oxygen Measurement Without Infrared Channel)..... 5-24

Figure 5-18. Oxygen Sensor with Infrared Channel................................................................ 5-25

Figure 5-19. OXS PCB Location of Measuring Points and Voltage Adjustment..................... 5-27

Figure 5-20. BKS PCB Location of EPROM and Battery Buffer Jumper (J7)......................... 5-28

Figure 5-21. BKS PCB Test Points........................................................................................ 5-29

Figure 5-22. BKS PCB Plug Locations.................................................................................... 5-33

Figure 5-23. BKS PCB Jumper Locations............................................................................... 5-34

Figure 5-24. OXS PCB Test Points.........................................................................................5-35

Figure 5-25. OXS PCB Plug Locations................................................................................... 5-36

Figure 5-26. Power Supply Connections................................................................................. 5-37

Instruction Manual

748441-D

April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Contents v

Model CAT 100

LIST OF TABLES

Table 2-1. Analog Output Terminal Assignments................................................................... 2-7

Table 2-2. Digital Output Terminal Assignments.................................................................... 2-8

Table 2-3. Optional Status Signals Terminal Assignments.....................................................2-8

Table 2-4. Optional Cross Compensation Analog Inputs........................................................ 2-8

Table 2-5. Optional RS232/485 Terminal Assignments.......................................................... 2-9

Table 2-6. Power Connections Terminal Assignments...........................................................2-9

LIST OF DRAWINGS

(Located In Rear Of Manual)

659921 Assembly Drawing, CAT 100

660198 Wiring Diagram, CAT 100

660210 Installation Drawing, CAT 100

660371 Diagram, Power Input and Ground Circuits

Instruction Manual

748441-D

April 2002

vi Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

Instruction Manual

748441-D

April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1

Model CAT 100

PREFACE

The purpose of this manual is to provide information concerning the components, functions, instal-

lation and maintenance of the CAT 100 .

Some sections may describe equipment not used in your configuration. The user should become

thoroughly familiar with the operation of this module before operating it. Read this instruction

manual completely.

DEFINITIONS

The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout

this publication.

DANGER .

Highlights the presence of a hazard which will cause severe personal injury, death, or substantial

property damage if the warning is ignored.

WARNING .

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not

strictly observed, could result in injury, death, or long-term health hazards of personnel.

CAUTION.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not

strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure,

condition or statement.

Instruction Manual

748441-D

April 2002

P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

INTENDED USE STATEMENT

The Rosemount Analytical 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.

SAFETY SUMMARY

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

impaired.

AUTHORIZED PERSONNEL

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.

DANGER.

ELECTRICAL SHOCK HAZARD

Do not open while energized. Installation requires access to live parts which can cause death or

serious injury.

For safety and proper performance this instrument must be connected to a properly grounded

three-wire source of power.

DANGER.

POSSIBLE EXPLOSION HAZARD

Do not operate without dome and covers secure. Ensure that all gas connections are made as la-

beled and are leak free. Improper gas connections could result in explosion and death.

Instruction Manual

748441-D

April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3

Model CAT 100

WARNING: TOXIC GAS

DANGER.

TOXIC GAS

This device may contain explosive, toxic or unhealthy gas components. Before cleaning or chang-

ing parts in the gas paths, purge the gas lines with ambient air or nitrogen.

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 con-

nections for leakage.

Keep all tube fittings tight to avoid leaks. See Sections 2-3 (page 2-11) and 6-2 (page 5-6) for leak

check information.

WARNING.

HAZARDOUS AREA 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).

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 modifi-

cation to this instrument.

Return the instrument to a Rosemount Analytical Service office for service or repair to ensure that

safety features are maintained.

Instruction Manual

748441-D

April 2002

P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

CAUTION.

PRESSURIZED GAS

This unit requires periodic calibration with a known standard gas. It also may utilizes a pressur-

ized carrier gas, such as helium, hydrogen, or nitrogen. See General Precautions for Handling and

Storing High Pressure Gas Cylinders, page P-5.

CAUTION.

HEAVY WEIGHT

Use two persons or a suitable lifting device to move or carry the instrument.

Instruction Manual

748441-D

April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5

Model CAT 100

GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH

PRESSURE GAS CYLINDERS

Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed

Gases" published in 1981

Compressed Gas Association

1235 Jefferson Davis Highway

Arlington, Virginia 22202

Used by Permission

1. Never drop cylinders or permit them to strike each other violently.

2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of

weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the

shade when located in areas where extreme temperatures are prevalent.

3. The valve protection cap should be left on each cylinder until it has been secured against a wall or

bench, or placed in a cylinder stand, and is ready to be used.

4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a

suitable hand-truck.

5. Never tamper with safety devices in valves or cylinders.

6. Do not store full and empty cylinders together. Serious suck back can occur when an empty cylinder is

attached to a pressurized system.

7. No part of cylinder should be subjected to a temperature higher than 125

°

F (52

°

C). A flame should

never be permitted to come in contact with any part of a compressed gas cylinder.

8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding,

precautions must be taken to prevent striking an arc against the cylinder.

Instruction Manual

748441-D

April 2002

P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

DOCUMENTATION

The following CAT 100 instruction materials are available. Contact Customer Service Center or the local

representative to order.

748441 Instruction Manual (this document)

COMPLIANCES

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

product name-rating plate.

Area Classifications:

USA

Class I Zone 1

AEx d e m IIB + H

2

T4

Canada

Ex d e m IIB + H

2

T4

European Union

ATEX, Category 2, Zone 1, IIB + H

2

T4

USA/Canada

Certified by Canadian Standards Association, an OSHA Nationally Recog-

nized Testing Laboratory (NRTL) for USA and Canada.

European Union

Conforms with the provisions of the EMC Directive 89/336/EEC, Low Volt-

age Directive 73/23/EEC, Potentially Explosive Atmospheres Directive

94/9/EC, including amendments by the CE marking Directive 93/68/EEC.

EC type Examination Certificate, LCIE 00 ATEX 6009 X.

Rosemount Analytical has satisfied all obligations from the European Leg-

islation to harmonize the product requirements in Europe.

Australia/New Zealand

Conforms with Electromagnetic Compatibility – Generic Emission standard

and AS/NZS 4251.1 – 1994 Part 1 – Residential, commercial, and light in-

dustrial.

Complies with the NAMUR RECOMMENDATION, Electromagnetic Com-

patibility (EMC) issue 1998.

N

9

6

0081

II 2 G

EEx d e m II B (+H

2

) T4

LCIE 00 ATEX 6009 X

®

C

US

NAMUR

Instruction Manual

748441-D

April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1

Model CAT 100

SECTION 1

DESCRIPTION AND SPECIFICATIONS

1-1 OVERVIEW

This manual describes the CAT 100 Continu-

ous Analyzer Transmitter.

The CAT 100 is a 1 or 2 channel Continuous

Gas Analyzer with FOUNDATION Fieldbus

communications. Its Class I, Zone I (IIB) + H

2

approved enclosure makes it suitable for in-

stallation in hazardous environments. The

field mountable housing design allows the

CAT 100 to be mounted close to the process

instead of in a remote shelter. This feature

greatly reduces installation and utility costs

while improving process efficiency.

The CAT 100 can continuously measure 1 or

2 components in a single analyzer using a

combination of Non Dispersive Infrared

(NDIR), Paramagnetic Oxygen, Thermal Con-

ductivity, and Electrochemical sensors. The

CAT 100 also features an optional customized

sample-handling module.

1-2 TYPICAL APPLICATIONS

The CAT 100 Continuous Analyzer Transmit-

ter supports a variety of industry applications,

drawing on more than 40 years of develop-

ment and process expertise in sensors, digital

signal processing and software technologies.

The CAT 100 can satisfy the most demanding

single or multi-component analysis require-

ments. More than 60 gas components can be

measured including:

Carbon Monoxide (CO) Carbon Dioxide (CO

2

) Methane (CH

4

)

Hexane (CH equiv.) (C

6

H

14

) Water Vapor (H

2

O) Oxygen (O

2

)

Hydrogen (H

2

) Helium (He) Argon (Ar)

Ethylene (C

2

H

4

) Propane (C

3

H

8

) Butane (C

4

H

10

)

Some standard industry applications include:

Petrochemical Refinery

•

Light Naphtha Isomerization

H

2

, CO and CO

2

in make-up Hydrogen

Gas to Combined Feed

H

2

in Scrubber Off Gas to Refinery Fuel

Gas Header

•

Catalytic Reforming

H

2

in Recycle Gas from Product Separa-

tor

H

2

in Net Gas from Net Gas Knockout

Drum

H

2

in CCR Nitrogen Header

H

2

in Surge Hopper Vent

•

Fluidized Catalytic Cracking

CO and O

2

Monitoring of Fluidized Cata-

lytic Cracking Regenerator Gas

•

Sulfur Recovery Units

Propylene in Feed to Sulfur Recovery

Plant

Petrochemical Complex

Ethylene in Primary and Secondary De-

Methanizer Overhead

CO

2

in Ethane-Ethylene Splitter

Propylene in Splitter Bottoms

Ammonia and Urea

H

2

, CO and CO

2

in Synthesis Gas

Utilities

H

2

in Cooling Gas in Turbine Generators

Continuous Emission Monitoring Systems

(CEMS)

Metals

H

2

in Endothermic Furnace

All Applications

Continuous Emission Monitoring Systems

(CEMS)

Instruction Manual

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April 2002

1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

1-3 DETECTOR METHODOLOGIES

The CAT 100 can employ up to two of four dif-

ferent measuring methods depending on the

configuration chosen. The methods are:

NDIR, Paramagnetic O

2

, Electrochemical O

2

,

and Thermal Conductivity.

a. Non-Dispersive Infrared (NDIR)

The non-dispersive infrared method is

based on the principle of absorption of in-

frared 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 ab-

sorption gives a measure of the concen-

tration 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 de-

tector signal thus alternates between con-

centration dependent and concentration

independent values. The difference be-

tween the two is a reliable measure of the

concentration of the absorbing gas com-

ponent.

Depending on the gas being measured

and its concentration, one of two different

measuring methods may be used as fol-

lows:

Interference Filter Correlation (IFC)

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 ex-

pected to be encountered in practice ab-

sorbs anywhere within the band.

The spectral transmittance curves of the

interference filters used in the CAT 100

analyzer and the spectral absorption of

the gases CO and CO

2

are shown in

Figure 1-1 (page 1-3). It can be seen that

the absorption bands of these gases each

coincide with the pass bands of one of the

interference filters. The forth interference

filter, used for generating a reference sig-

nal, has its pass band in a spectral region

where none of these gases absorb. Most

of the other gases of interest also do not

absorb within the pass band of this refer-

ence filter.

The signal generation is accomplished

with a pyroelectrical (solid-state) detector.

The detector records the incoming infra-

red radiation. This radiation is reduced by

the absorption of the gas at the corre-

sponding 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 mate-

rial.

Instruction Manual

748441-D

April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3

Model CAT 100

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

Transmittance (%)

0 18 36 54 72 90

Transmittance (%)

0 15 30 54 60 75 90

CO

2

CO

A

bsorption Band

HC CO

2

CO

Reference

3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600

Wave Length (nm)

Instruction Manual

748441-D

April 2002

1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT 100

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 pneu-

matic detector.

The pneumatic detector compares and

evaluates the radiation from the measur-

ing and reference sides of the analysis

cell and converts them into voltage sig-

nals proportional to their respective inten-

sity.

The pneumatic detector consists of a gas-

filled absorption chamber and a compen-

sation chamber which are connected by a

flow channel in which a Microflow filament

sensor is mounted. This is shown Figure

1-2.

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 win-

dow which is transparent for infrared ra-

diation. 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 absorp-

tion chamber is heated, expands and

some of it passes through the flow chan-

nel into the compensation chamber.

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 ref-

erence side. Absorption chamber gas be-

comes 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 elec-

trical pulses which are processed into the

corresponding analyzer output.

Figure 1-2. Opto-Pneumatic Gas Detector

Compensation chamber

A

bsorption chamber

CaF

2

Window

Flow channel with

Microflow sensor

Instruction Manual

748441-D

April 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5

Model CAT 100

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 Cor-

relation (IFC) method, the infrared radia-

tion then passes through combinations of

interference filters. In the case of the

opto-pneumatic method, the infrared ra-

diation 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 di-

rectly in the appropriate physical concen-

tration units such as percent volume,

ppm, mg/Nm

3

, etc. This is shown in

Figure 1-3 (page 1-5).

Figure 1-3. Overall NDIR Method

MOTOR

A

dapter Cell

(high measuring range)

Light Source

Chopper Blade

Duplex Filter Disc

Analysis Cell

(measuring side)

Analysis Cell

(reference side)

Filter Cell

Gas Detecto

r

Preamplifie

r

Chopper Blade

A

nalysis Cell

(undivided)

Filter Cell

Preamplifier

Pyroelectric Detector

(solid-state detector)

Instruction Manual

748441-D

April 2002

1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model CAT100

b. Paramagnetic Oxygen Method

The paramagnetic principle refers to the

induction of a weak magnetic field, paral-

lel and proportional to the intensity of a

stronger magnetizing field.

The paramagnetic method of determina-

tion of oxygen concentration utilizes nitro-

gen 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. Ni-

trogen (N

2

) is used because it is diamag-

netic or repelled by a magnet.

A small mirror that reflects a light beam

coming from a light source to a photo de-

tector, is mounted on the platinum ribbon.

A strong permanent magnet specifically

shaped to produce a strong, highly inho-

mogeneous 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 photo detector 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 re-

storing 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, perma-

nent magnet, processing electronics, and

a temperature sensor. The temperature

sensor is used to control a heat ex-

changer to warm the measuring gas to

about 55

°

C. Refer to Figure 1-4 (page 1-

6).

Figure 1-4. Paramagnetic Oxygen Analysis

Permanent Magnet

Platinum Wire

Mirror

Quartz Sphere(s)

Photo detecto

r

Light

Source

Wire Loop

A

mplifier

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